DS-Controller-Operation Manual
Contents
1. Repeatability 0 05 E Wwe e qe qe pm p Motors AC Servo Motor Together with the motor on the spindle A B Z phase Voltage output Input voltage 5V Homing pulse 1 pulse Yrotation Hardened alloyed Steel Extruded aluminium A6063S T5 White alumite treated Stainless steel Aluminium die cast baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Motor Cable 11 conductor composite cable 5 m standard length Grease Ballscrew Lithium type grease SJUBUOGLUGD UJEN Jo unions Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Payload 2 3 Horizontal 4 kg Vertical 1 kg Moment 2 4 5 000 km life expectancy Ma 4 9 Mb 6 8 Mc 11 7 MC 7 8 Overhang Load Length L 5 Ma 150 or less Mb Mc 150 or less al bra Magnetic brake energized to release Ata SUE kr 5 seconds Brake forne ER the attached object is the jur uopsoldd en load momen Fix base snel toa flat strong Rare 1 Atan acceleration of 0 3 G and a speed of 800 mm sec 1 Direction of load moment is Mb direction E A E enh e SES 5p Ma direction Data of the DS Series Specifications DS NENNEN 4 1 2 Medium Speed Type DS S5M Rated Output Rated Speed 400 Rated Thrust Repeatability Unit Weight 14 1 6 AC Servo Motor n l Encoder Together with the motor on the spindle pola Di A B Z phase Voltage output BPhse Ll I Ll JU EEE Input voltage 5V Ph2. DS When the READY signal turns ON the READY lamp green on the controller front panel lights up The program number from the external device is input as a BCD code Note 1 When a position number greater than 501 is designated the signal is disregarded Note 2 When there is no data in the designated position number the signal is disregarded Note 3 If homing has not been performed and a position is designated and a start signal input the actuator will home first and then move to the position When the move is completed a positioning end signal is output When an emergency stop signal from the external device is input or if the controller malfunctions the controller turns the servo OFF READY lamp turns OFF When the ALARM signal turns ON the ALARM lamp red on the controller front panel lights up DS Controller DS 3 Timing of Signals When exchanging signals with an external device timing is critical See the timing charts that follow Timing of Signals T1 The time from the READY signal ON to homing start input T1 50 ms or more T2 The time from the start signal ON to the P End signal OFF T2 within 15 ms T3 The time from the P End External Start signal ON to when the external start signal input Input can be entered T3 50 ms or more T4 The time after the input of Movement the external start signal until the Start of movement TA app 50 m
3. II External Device for t example PLC J Page 1 19 24V PC Software option POWER EMG ENABLE m i EMG S DS Controller DS 1 Connect the motor encoder brake cable coming from the actuator to the connector 2 Connect the teaching pendant to the controller After connecting turn the PORT Switch ON If it is OFF the teaching pendant will not work when the power is turned ON 3 Supply the DC 24 V power to the controller terminal block power 4 If the Code display shows arm B 5 Sra Pra ry din sequence then the DS Controller is ready to operate Erk then the EMERGENCY STOP input will release r E5J then either a CPU reset has been input or I O current is disconnected The controller preparation is now complete Note The controller terminal block EMG is for connecting an emergency stop switch and is a b type contact input normally closed When the unit is shipped it is shorted and the emergency stop is released Page 1 20 DS Controller DS 1 7 2 Diagram of the External Device Connector The following is an example of connections with an external device in the program mode Terminal Block 6 pin Signal Name Program Mode 24 V Output 4 EMGSW EMGSW 6 ENABLE I O Connector 34 pin ov Distribution VoltageO
4. 3 7 34 21V Distribution Voltage 24 V Input _grey blueD Note PRG Program u Output W oO 001 002 003 005 007 008 010 012 013 014 015 300 301 302 303 304 305 306 307 jean 9 DM AR 320 a ot ed mE SE ore o5 Be E ES d Please use Pin No 18 NC to Pin No 4 NC for inputting program numbers Page 1 11 DS Controller 1 44 TEACHING RS232PORT D Sub 25 DTE Special Pp RX DE TEN 2 3 BEES hort Circuit 6 DSR 7 SGGND O o 8 E O Be Bi TE EMGSW 10 NC dno NC O 12 EMGSTOPS 13 EMGSTOPSI 1 2 3 4 5 7 10 11 12 13 Connection cable to an IBM PC 9 pins RS232 Pin No Signal Name IBM PC 4 pair shielded wire DB 9S or comparable SPMC 8DG 6 V Output DS FENAE Je EMG STOP NC NC NC NC DTR NC NC NC PORTSW Ta RS 232C D Sub connector DB 25P or comparable shield LEG mA CAN esse ul 6 DSR 2 RXD 7 RTS 3 TXD 8 CTS 4 DTR 9 RI 5 GS Connect the shielded cable to the shell cable clamp section 600090 0 1 GP FG 2 TXD 3 RXD 4 RTS 5 CTS 6 DSR 7 SG GND 20 DTR e In the case of RS232C never connect pin numbers 12 13 18 19 23 and 25 since these are signal wires for the teaching pendant e Pin numbers 4 and 5 are shorted e Since pin numbers 18 and 19 are connecting termi
5. Note NC No contact Do not use number Pin No 18 NC to Pin No 4 NC since these are for program number input Position mode can be used when program number inputs are 0 OFF When using the controller in position mode use pin number 24 Port No 004 to Pin No 29 Port No 014 for position number input Homing is performed when position number inputs are 0 OFF Please note that when the I O connector external 24V power is not connected the controller considers all input ports and program inputs to be 0 OFF Page 1 10 DS Controller DS Program Mode I O Connector 34 pin 1 OV Distribution VolageO V orange redA 1 PRGNo orange blueA PRGN gmyfdA grey blue A PRGNo8 whit redA PRGNel0 whit bleA PRGNe20 yellow redA Reserve yelowbleA CPURESET pink redA 00 Start Input Program pinkblueA 01 Userin orange red B 02 Userinpu orange blueB 08 o 05 L 06 EEE o 008 009 jan UO o Nja EIS grey red B grey blue B GIE white red B white blue B yellow red B EIE yellow blue B pink red B 010 ser Input _ pink blueB a E c orange red C orange blue C C e greylred C c os 1 Uselhpu whit redC 3 Alarm Output white blue C 320 Ready Output yellow red C jan
6. Page 2 3 DS Slider Type DS 2 2 3 Wiring Cable The actuator cable is resistant to bending fatigue but it is not robot cable so avoid housing the cable in movable wire duct with a small radius In an application where the cable cannot be properly anchored try to place the cable so that it sags only under its own weight or use self standing type cable hose as large radial wire duct to limit the load on the cable 2 2 4 Adjusting the Home Position After installing the actuator perform the homing operation to confirm home H ome direction can be changed with the parameters If you allow a large offset amount the moving range is limited by that amount If you specify an offset amount greater than 1mm you will have to reset the software limit and reduce the stroke by that amount Note To change the home offset amount requires the optional PC software By changing the homing direction please contact the technical office of IAl 2 2 5 Load on the Actuator Do not exceed the load shown in the specification table at Chapter 4 Please note in particular the thrust and allowable overhang length and the load weight The base of the actuator warps easily when it is used with an overhang so please keep the Ma and Mc moments under of the rated value Mb zz Ms Ma Sn Page 2 4 DS Slider Type DS A3 Maintenance 2 3 1 Maintenance Schedule Perform maintenance work according to the schedule below Maintenance Checkpoints Vis
7. Type DS4 DSA A4 DS 1 Remove the screw cover to inspect the brake 1 Visually check the conditions of the brake Type DS5 DS A5 1 Peel off the seal to inspect the brake 1 Visually check the condition of the brake Note When the motor is folded backwards S type you must change the direction to the right or the left Page 3 10 DS Arm Type 2 Adjusting the brake gap DS Normally the inner driver requires no maintenance but if adjustments are necessary use the following procedure 0 5 Inner driver Armature Brake Cross Section 3 Attaching the cover x Stator Ballscrew axis Page 3 11 1 We recommend the actuator be placed on a horizontal surface when adjusting the brake gap If you are doing the adjustment with the actuator in a vertical position first move the slider to the stroke end 1 Release the brake and loosen the two set screws 1 Set the inner driver about 0 5mm from where it would hit up against the armature Follow the procedure used to remove the cover in reverse order and reattach the screw cover and pulley cover After you finish the inspection replace the cover as it was at the start Data of the DS Series Specifications DS 4 Data of the DS Series Specifications 41 Specifications for the Slider Type 4 1 1 High Speed Type DS S5H ccm cede EDT Rated Output Rated Speed Ee Rated Thrust a I E I i
8. Y ALARM i output i p gt ALARM signal Nl When the ALARM signal DEARMGSIEDSEOIN confirmed turns ON the ALARM lamp red on the controller front Y panel lights up ALARM processing i Page 1 24 DS Controller DS 2 Timing of Each Signal When exchanging signals with an external device timing is critical See the timing charts that follow Timing of Each Signal Ready T1 The time from when the Output READY output turns ON until the external start signal can be input T1 50 ms or more Program No 4 Input The time from the program number is input until the external start signal can be input T2 30 ms or more T3 The time from the input of the external start signal T3 30 ms or more T4 Actuator The time after the input a es ans of the external start Movement signal until the Start of movement T4 app 50 ms Page 1 25 DS Controller DS 1 8 2 Operation Using the Positioning Mode n The positioning mode consists of operation from the teaching pendant operation using a PC software and operation based on the external start signal selection This section explains the last method Operation Based on the External Start Signal Selection 1 Homing Controller External Device 4 Power ON Power ON j READY 4 output READY signal ON gt READY signal confirmed d Y Set all Position No Once the READY signal is ON command to O
9. No Contact Page 1 22 DS Controller DS 1 8 Moving the Actuator There are two ways to move the actuator One is the program mode where a program in the memory drives the actuator and the other is the positioning mode where the actuator is moved between stored positions 1 8 4 Program Mode There are two methods of operating the actuator in the program mode The first is operation from the teaching pendant and operation using a PC software which are used for simple operating checks during program debugging on a trial run The second is automatic operation based on parameter settings and operation based on selection of external signals which are used in general application examples on site The following section explains the second method Parameter setting is done either by using the teaching pendant or a PC software Automatic operation using the parameter setting Set Automatic Start Program No Enter the number of the program to be automatically started in the system parameter item Auto Start Program No located on the controller side Reset the controller by releasing the emergency stop after it occurs or by turning the power OFF then On Reset the Controller again or RESET CPU After resetting the controller the program number that was entered in the parameters automatically starts Automatic Program Start Precautions when using an auto start program The servo actuator will start au
10. 1 7 1 Connection Method deett ete e ine druide 1 19 1 7 2 Diagram of the External Device Connector eese ertet tette tenete tette nennen 1 21 ES MOVING the ACUO Scant 1 23 1 6 1 MUN 1 23 1 8 2 Operation Using the Positioning Mode esee ener 1 26 1 9 Emor Code Sieniniai eaa eite kt ee ae bee aet e M aO tet Et eee god 1 30 1 10 Maintenance i toe tite Go Ove Ores npa UIN ea ax EUR DIEN CREE zebra EPIS ERR 1 31 2 DS SLIDER TYPE 2 1 2 1 Part Names and function osii cee e cece eee ee cece eee teen ee ee ee eene mme nene nhe nennen nnns 2 1 1 Part Nam s sot edite de io e tete tds pre ete te e tendras 2 1 2 Operating ENVITONINENE x esee etie EH Uee ede a ate eere re e ERREUR eS horse 2 2 Installation E Delete 2 2 1 Installing the Actuator ses etes ee etie tiec a ele ec unless 2 2 2 Attaching the Workpiece 2 2 3 Wiring Cable 2 2 4 Adjusting the Home Position ves e dex 2 2 5 Load ON the A CIUALON ins sessiciisas success edet i et e dee ach uses ese ses e ec E A ES 2 4 23 EIDEM 2 5 2 3 1 Maintenance Schedule scc vc ea cde date edite ed 2 5 2 3 2 Cleaning the POXUFIDE iae e YR UN ARR EUER PRXTER RAN EINER EAE E a EON e EE NM ul P ERA RN NR RR 2 5 2 3 3 D bricationl i a vacet obi E eet aU RE eel ver ie bes in eau eie EE tee cle 2 7 Table of Contents 2 3 4 3 DS ARM TYPE Checking t
11. PORT PORT connector This is the connector for connecting the teaching pendant or a personal computer Page 1 4 DS Controller DS Motor Encoder This is the connector for connecting the actuator motor encoder cable incl brake Brake connector M3 screw for the ground connection of I 0 cable External equipments This is the connector for connecting external equipments and for the 24 V power of connector I 0 board Power and emergency stop This ist the terminal for 24 V power terminal block The two ENABLE terminals must be always kept shorted either with wire or contact point The driver power will go off and become Driver Alarm EA1 if the short at ENABLE ist released when servo is on In this case it will recover after the controller is powered on again Note Please do not connect the two ENABLE terminals to other circuits At the time the unit is shipped EMG terminals and ENABLE terminals are shorted and connected to emergency stop connector I POWER EMG ENABLE ENABLE Emergency Stop The user should satisfy the conditions given in the table below with respect to the power lines that are connected Suitable power line 2x L5 mn Standard line length of the MPG cable 5m 11 leads Note This controller does not have a power switch Page 1 5 DS Controller 1 3 3 Explanation of the Code Displays Fd pn pn Sr denies e E En CES per Por e By x x x fou d ed
12. bd bd Cd E m x gt gt gt gt gt gt gt gt Open display Serial I O check display Servo check display Program check display Ready display Flash memory copy display Flash memory copy complete display Update display Emergency stop display CPU reset Homing display Startup program No display Position No display 001 500 Interrupt error display Software error display Other error display Page 1 6 DS DS Controller DS 1 4 Specification 1 4 1 Controller Specification Power Supply DC 24 V 10 1 A rated Maximum 2A during acceleration Ambient Temperature amp Humidity e Temperature 0 50 C e Humidity max 95 relative humidity non condensing Operating Environment Free of corrosive gas e No excessive dust IP 20 Immunity to Interference Acc to DIN EN 500822 Unit Weight 860 g Safety Features Driver alarm Motor excess current Excess voltage Driver temperature check Overload check Software limit check length of stroke Multi tasking Control Super SEL Controller Memory Capacity e 32 programs e 1000 steps e 500 positions Memory Device CMOS CMOS buffer battery Input Output 24 V DC Dedicated inputs 7 PRG No 1 2 4 8 10 20 CPU Reset Non mstilated Dedicated inputs 1 START User inputs 15 User inputs 2 READY ALARM User outputs 6 Data Input Method RS232 Teaching pendant or RS232 Communicatio
13. strong frame 1 Atan acceleration of 0 3 G and a speed of 330 mm sec 1 Direction of load moment is Mb direction L Mc us ue un ZZ ae amp Gea ap direction Page 4 6 Data of the DS Series Specifications Page 4 7 DS Data of the DS Series Specifications DS 4 1 6 Low Speed High Thrust Type DS S4L qu Rated Output Rated Speed Rated Thrust Repeatability 0 02 vonesyjpeds EC OX Eee VE AC Servo Motor a Encoder Together with the motor on the spindle A B Z phase Voltage output Input voltage 5V Z RNase Homing pulse 1 pulse Yarotation 8 mm Lead 2 5 mm Rolled thread C10 Backlash 0 1 mm or less Guide Integrated with base DS dedicated Motor Ballscrew Connection Integrated motor axis and ballscrew achsis Base Slide Hardened alloyed Steel Side Cover Extruded aluminium A6063S T5 White alumite treated Dust Shield Stainless steel Motor Housing Aluminium die cast baked finish Weugdwen UIEN jo eunjonuis Encoder Cover Front Cover Polyacetal plastic Slide Cover Motor Cable 11 conductor composite cable 5m standard length Grease Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Maximum Thrust 1 156 8 Payload 2 3 Horizontal 5 kg Vertical 4 5 kg Moment 2 4 Nm 5 000 km life expectancy Ma 2 7 Mb 3 9 Mc 6 8 Overhang Load Length L 5 Ma 120 or less Mb Mc 120 or less 1 Optional brake Magnetic brake energized to release Brak
14. 1 131 4 Payload 2 3 Vertical 4 kg Page 4 11 jur ugn amp olddy Data of the DS Series Specifications DS Moment 2 4 At a speed of 10 mm sec for 5 seconds 5 000 km life expectancy Ma 4 5 Mb 5 4 Mc 4 1 Even load distribution on the slider Fix base securely to a flat strong frame For horizontal use load should be applied in the thrust direction as shown in the drawing If the slider becomes deformed it will cause poor movement At an acceleration of 0 2 G and a speed of 200 mm sec Direction of load moment is Ma 4 2 3 Medium Speed Type DS A4M uo Bop ads t rt o E a a m 2 Q Qo i a Qo 3 a Rated Output w Rated Speed 330 Rated Thrust Repeatability Encoder AC Servo MoBsfcoder Signals Together with the motor on the spindle APhase n 1 exer ape b A B Z phase Voltage output B Phase ZPhse J4 LOW Input voltage 5V Homing pulse 1 pulse rotation Dry single head on when deenergized electromagnetic brake mer 0 m 8 mm Lead 10 mm Rolled thread C10 Backlash 0 1 mm or less Motor Ballscrew Connection Integrated with base DS dedicated Timing belt Reduction ratio 1 2 Hardened alloyed Steel Extruded aluminium A6NO1S T5 White alumite treated Extruded aluminium A6063S T5 White alumite treated Aluminium die cast baked finish Encoder Cover Pulley Cover Polyacetal plastic Motor Cable 11 conductor composite cable 5m standard le
15. DS Controller Operating Manual IAI Industrieroboter GmbH Ober der R th 4 D 65824 Schwalbach am Taunus Tel 49 6196 8895 0 Fax 49 6196 8895 24 E Mail info iai gmbh de Internet http www ntelligentActuator de Publication No IAI E 036F Publication Date February 2001 This publication was written to assist you in better understanding this part of your IA system If you require further assistance please contact IA Technical Support at 49 6196 8895 0 or Fax 49 6196 8895 24 during regular business hours Z1 intelligent Actuator IAI Industrieroboter GmbH Ober der R th 4 D 65824 Schwalbach am Taunus Germany Tel 49 6196 8895 0 Fax 49 6196 8895 24 IAI America Inc 2360 W 205th Street Torrance CA 90501 1483 US A Tel 1 800 736 1712 Fax 1 310 320 4553 IAI Corporation 645 1 Hirose Shimizu City Shizuoka 424 01 Japan Tel 81 543 64 5105 Fax 81 543 64 5182 October 1998 IAT industrieroboter GmbH All rights reserved No portion of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechnical recording or otherwise without the prior written permission of IAI Industrieroboter GmbH Disclaimer The information and technical data contained herein are subject to change without notice AI Industrieroboter GmbH assumes no responsibility for any errors or omissions regarding the accuracy of the information contained in this pu
16. FF 0 the READY lamp green on the controller front panel lights up External na eR debes start input Homing is performed when a position number inputs from the external device are OFF N Pis signa Start signal ON 0 and the start signal is confirmed input 4Y After homing is completed the positioning end signal is 4 ee output and the controller goes into a wait stage Homing complete Positioning end Signal 4 l Positioning end gt In position signal N signal ON confirmed Y NOTE After homing based on external devices commands from the external device have priority When switching over to an operation from the teaching pendant or using a PC software perform homing after cutting the power once Page 1 26 DS Controller 2 Positioning i YN Homing complete Homing Complete Move to command position Bee p J arc Y ALARM signal ON Emergency stop signal confirmed output Position No input lt Exter input Positioning a Emergency stop input ALARM output External Device or READY signal confirmed Y Position No command nal operation Start signal ON I O processing end output Emergency stop c switch ON LJ i ALARM signal confirmed LY ALARM processing Y Page 1 27 I O processing
17. S Controller DS 1 3 2 Functions CODE display CODE This is a 3 digit display device that indicates the operating status of the controller LED display e READY This indicates that the controller is ready to be operated e ALARM This is the display when there is a malfunction in the DS system e BAT This indicates battery voltage is low Brake release switch BRAKE RELEASE The brake is released e NORMAL The brake is ON This is the normal setting The brake release switch is ENABLEd during the servo free state indicated below 1 From the time the power is turned ON until the homing routine is performed 2 When SVOF is selected during direct teaching 3 When an alarm occurs PORT switch PORT e ON The TEACHING RS232PORT is ENABLEd However when the TEACHING RS232 PORT connector is not connected an emergency stop Occurs OFF The TEACHING RS232PORT is disengaged However even when the TEACHING RS232PORT connector is not connected the emergency stop is released Note When the controller is powered up plug in or remove the TEACHING RS232PORT connector when the PORT switch is OFF Function switch e BAUR This is the switch for changing the Baud rate e COPY This is the switch for COPY from ROM to FLASH memory e FR This is the switch for changing FLASH and ROM Note At the time the unit is shipped all switches are set to OFF so use them as is under normal circumstances TEACHING RS232 TEACHING RS222
18. V _ 1 mRGNoIhpt pe PRG No 2 Input Fr Sag _ PRGNo4hpu 1 PRGNel Rpt PRGNo 20Impu Reserve oOo eugsr x0 Start Input Program oi Usernpt OE o J o ow c5 06 wor 008 9 o oM 001 002 003 005 007 008 010 011 012 013 J 014 05 Usrlipt Wg o j 305 06 S 307 O2 U 03 User Input 0M U NEC 7 Owp 3 PASS aa 305 User Outpt 2 307 Verowu tds sav Distribution Voltage 24 Vinpur 24V OV Page 1 21 DS Controller DS The following is an example of connections with an external device in the position mode Terminal Block 6 pin Position Mode Lu ETUR 4 a 6 Enable I O Connector 34 pin Function 1 ov Distribution Voltage 0 V O o T NI pg p M nme CPU RESET NENNT 00 External Start Input dl 2 Lun Hold Input NC NC id BCD Switch Position No 1 Input or PLC Position No 2 Input 10 006 Position No 4 Input Position No 8 Input Position No 10 Input 09 Position No 20 Input 10 Position No 40 Input Position No 80 Input ei Position No 100 Input 10 Position No 200 Input Position No 400 Input os C Q Alarm Output s E SENE IND Ready Output EP Position Complete S Output C C C c C 34 L zav Distribution Voltage 24 V Input S 24V OV NC
19. ase Homing pulse 1 pulse Yarotation uonesyjoeds tn re o d a m 5 Q a 3 a e a Extruded aluminium A6063S T5 White alumite treated Dust Shield Stainless steel Aluminium die cast baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Motor Cable 11 conductor composite cable 5m standard length Grease Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Maximum Thrust 1 65 7 Moment 2 4 5 000 km life expectancy Ma 4 9 Mb 6 8 Mc 11 7 MC 7 8 Overhang Load Length L 5 Ma 150 or less Mb Mc 150 or less At a speed of 10mm sec for 5 seconds 5 When the centre of gravity for the attached object is 1 2 the Even load distribution on the slider When disigning work consider overhang length oad moment Fix base securely to a Tat strong Trame 1 Atan acceleration of 0 3 G and a speed of 400 mm sec Page 4 2 1 Direction of load moment is Mb direction i Z Mc I 3 Horizontal 8 kg Vertical 2 kg direction Data of the DS Series Specifications DS Optional brake Magnetic brake energized to release Brake torque 11 76 Ncm 4 1 3 Low Speed Hugh Thrust Type DS SSL WE a alee ee Poe are eee Raum W 2 Rated Speed mme w OOo O O rast I E SE Repeatability 0 02 ee wwe ee e p T P Signals ji Motr AC Servo Motor ncoder Encoder Together with the motor on the spindl
20. blication DS Dynamic Series DS Series Ultra compact coupling free design Minimum width 40 mm height 46 mm length 210 mm Assembly parts made exclusively for the DS Series Ballscrew guide motor encoder rubber seal and cable Up to 500 positions programmable Effectively dust guard made of stainless steel Easy programming Variable acceleration and deceleration high speed motion control Extremely competitively priced IAl Industrieroboter GmbH Ober der R th 4 D 65824 Schwalbach am Taunus Tel 49 6196 8895 0 Fax 49 6196 8895 24 E Mail info iai gmbh de Internet http www IntelligentActuator de Publication No IAI E 036F Publication Date February 2001 Foreword DS Thank you very much for selecting the Intelligent Actuator DS series actuator controller system The DS series is compact easy to use and can control the actuator and peripheral devices with ease Also the SEL language used in the DS series makes it possible to perform high level control with simple expressions Please read through this manual carefully to gain an understanding of the proper method of operating and handling the DS controller and actuator Foreword DS Proper Use of the DS Actuator Safety Precautions Basic Use Please do not operate the actuator other than as described in this booklet e Do not come within the moving range of the actuator when the actuator is in operation or is ready to be op
21. carefully to make sure it is correct before turning the power ON since miswiring can lead to misoperation Page 1 1 DS Controller DS 1 2 Warranty Period and Scope of Warranty 1 This product is under warranty for a period of one year from the date it is shipped to the customer If the product breaks down due to a manufacturing defect during this period IAI will repair it at no cost 2 Thefollowing are not covered under the warranty even if the product is still under the warranty period Damage due to incorrect handling or use that does not adhere to the instructions in the user s manual When electrical or mechanical revisions have been performed on the product Part wear when traveling distance has exceeded 5 000 km Breakdown or damage caused by fire earthquake or other natural disasters Any other breakdown or damage that is not recognized as the company s responsibility Page 1 2 DS Controller 1 3 Part Names and Functions 1 3 1 Part Names Controller Code display GODE DS LED display EENE a CAL Ai OJBAT Brake release switch BRAKE e Hic zur Function switch TEACHING RS232 PORT TEACHING RS232 PORT connector PORT switch IAI Corporation Ground terminal Power and emergency stop terminal block SING DWF 190d Motor Encoder Brake connector External equipments connector I O D
22. cifications DS Guide Shell Albania Grease No 2 Mobil Mobilux No 2 39 2 Maximum Thrust 1 Payload 2 3 Moment 2 4 Nm 5 000 km life expectancy Brake torque 11 76 Ncm Horizontal 4 kg Vertical 1 kg Page 4 5 Data of the DS Series Specifications DS 4 1 5 Medium Speed Type DS S4M Rated Output Rated Speed Rated Thrust Repeatability 0 02 uojjeoypeds BE EEE Ve AC Servo Motor CI Encoder Together with the motor on the spindle A B Z phase Voltage output Input voltage 5V Homing pulse 1 pulse Yarotation 8 mm Lead 5 mm Rolled thread C10 Backlash 0 1 mm or less Guide Integrated with base DS dedicated Motor Ballscrew Connection Integrated motor axis and ballscrew achsis Base Slide Hardened alloyed Steel Side Cover Extruded aluminium A6063S T5 White alumite treated Dust Shield Stainless steel Motor Housing Aluminium die cast baked finish jueugpduo UEN jo Enorus Encoder Cover Front Cover Polyacetal plastic Slide Cover Motor Cable 11 conductor composite cable 5m standard length Grease Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Horizontal 5 kg Vertical 2 5 kg Moment 2 4 Nm 5 000 km life expectancy tional brake Magnetic brake energized to release 1 Ata Ba 10 mm see for 5 seconds ay When the Centre rgized Br the attached object is the Brakenterquein 1 76 Nem yur vonsolddy load moment Fix base securely to a flat
23. ctor composite cable 5m standard length Grease Ballscrew Lithium type grease DE Guide Shell Albania Grease No 2 Mobil Mobilux No 2 weusdwsg UEN jo gunjoruis Moment 2 4 5 000 km life expectancy Ma 2 7 Mb 3 1 Mc 2 9 yur vonsolddy Thrust direction Thrust direction Page 4 14 Data of the DS Series Specifications DS At a speed of 10 mm sec for 5 seconds Even load distribution on the slider Fix base securely to a flat strong frame For horizontal use load should be applied in the thrust direction as shown in the drawing If the slider becomes deformed it will cause poor movement At an acceleration of 0 2 G and a speed of 165 mm sec Direction of load moment is Ma 4 7 Page 4 15 Parameter 5 Parameter Page 5 1 DS Parameter Page 5 2 DS Parameter Page 5 3 DS Parameter Page 5 4 DS Parameter Page 5 5 DS Parameter Page 5 6 DS
24. e A Phase ABZ phase Voltage output B Phase ZPhse J LHW Homing pulse 1 pulse Yarotation Input voltage 5V Encoder Cover Front Cover Polyacetal plastic Slide Cover Se u weusdwsg UIE jo gunjonuis Page 4 3 r1 vonepiddy I E a speed of 10mm sec for 5 seconds 5 When the centre of gravity for the attached object is 1 2 the Data of the DS Series Specifications DS Moment 2 4 Nm 5 000 km life expectancy Ma 4 9 Mb 6 8 Mc 11 7 MC 7 8 Overhang Load Length L 5 Ma 150 or less Mb Mc 150 or less Optional brake Magnetic brake energized to release Brake torque 11 76 Ncm 4 1 4 Low Speed Hugh Thrust Type DS S4H pu Rated Output Rated Speed Rated Thrust Repeatability AC Servo Motor Encoder Together with the motor on the spindle A B Z phase Voltage output Input voltage 5V Homing pulse 1 pulse Yrotation 8 mm Lead 10 mm Rolled thread C10 Backlash 0 1 mm or less Integrated with base DS dedicated uonesyjpeds Motor Ballscrew Connection Integrated motor axis and ballscrew achsis Base Slide Hardened alloyed Steel t re o 5 d a m 2 Q a i a Qo m a Extruded aluminium A6063S T5 White alumite treated Dust Shield Aluminium die cast baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Motor Cable 11 conductor composite cable 5m standard length Grease Ballscrew Lithium type grease Page 4 4 Data of the DS Series Spe
25. e the timing belt but generally the belt has a lifetime of so many millions of rotations The more practical approach is to replace the belt if any of the following conditions occur The belt end or belt teeth have worn away There are cracks in or other damage to the belt or teeth The belt breaks If you need to replace the belt please contact IAI Page 3 8 DS Arm Type 3 Replacing the timing belt Follow the procedure below to replace the timing belt 2 Motor pulley amp Motort bracket Timing belt 4 Adjusting the tension of the timing belt Large pulley Motor bracket Motor pulley Hexagonal bolt M4x20 6 1mm F 100N Check tension Page 3 9 DS 1 Mark the pulley and motor bracket so that you do not change the home position 1 Loosen the four bolts 1 Put the new belt on while pushing the motor up 1 After the new belt is in place do the same procedure in reverse to reassemble After you change the timing belt it is necessary to readjust the tension As shown in the upper diagram at left push the motor pulley up then adjust the tension and set it Use the method shown in the left lower diagram to check whether the tension of the timing belt is suitable To put the belt on match it to the marked position DS Arm Type 3 3 6 Inspecting and Adjusting the Brake 1 Brake inspection Stator Set screw Armature Inner driver Seal
26. ect the controller to the unit then release the brake with the brake switch After releasing the brake pull the slider to the stroke end Turn off the controller power before proceeding to the next step Remove the four mounting screws from the screw cover The cover can be removed using a 1 5mm hexagonal wrench Rest the actuator on the mounting surface and check to see that a O 1mm thickness gauge cannot be inserted at the four mounting holes Affix the actuator using the mounting holes in the base If the bolts go into a steel surface then use hexagon sockets with the length shown in 1 and if the surface is a light metal use the length in 2 Actuator 1 2 DS S5 M4x12 DS S4 M3x12 After mounting the actuator reattach the screw cover Page 3 2 DS Arm Type DS 3 2 2 Attaching the Workpiece Tapped holes for mounting workpiece Use the four tapped holes at the top of the slider to attach the workpiece Slider There are 4 M4 screws for attaching the workpiece to the slider To ensure the slider does not become deformed when the workpiece is attached check to make sure the surface where the workpiece rests is flat A deformity in the slider causes stiff movement and shortens the life of the actuator Do not exceed the load indicated in the specification tables at chapter 4 Please note in particular the thrust allowable overhang length and the load weight Keep the overhang at the upper portio
27. elay coils Note Use the shortest possible wiring between the surge absorber and the noise creating device Use of excessively long wiring will decrease the performance of the surge absorber The most effective method is to install a surge absorber and surge killer in parallel to reactance load solenoid and relay coils This will reduce noise in a wide band of frequencies Surge Absorber Metal Oxide Varistor or comparable Surge Killer Resistor Capacitor Snubber Page 1 17 DS Controller DS DC solenoid valve magnetic switch relay Install a diode in parallel with a coil Diode Capacity is determined by the load capacity Note In the case of DC power be carefull not to exceed the diode polarity as this can lead to a breakdown of the diode inside the controler or of the DC power Circuit Example Output AC 230 V DS Controller K1 Valve Page 1 18 DS Controller 1 7 Connections 1 7 1 Connection Method DS Please make sure that all connectors are plugged in correctly and securely Excluding the TEACHING RS232 PORT do NOT plug or unplug the connectors while the power is ON Teaching Pendant option 3m DS Controller Controller 5m Servo Actuator OV
28. erated Maintenance Always unplug the electric cord prior to doing any maintenance work While doing maintenance work make sure that a sign indicating work in progress is clearly visible e Make sure that no one can inadvertently turn the power back on e If there is more than one person working let the other person know what work you are about to perform DS Controller Noise Prevention e AC load Install a surge suppressor parallel to the coil e DC load 24 V DC Attach a diode parallel to the coil Grounding good poor other DS Controller other equipment equipment Q gt Table of Contents DS 0 SAFETY 0 1 0 1 Classification of Safety Notes ssssessessessseseseeeen enne enne nennen nnne nnns nnne 0 1 0 2 Intended se utet nette etre ta eet dela a crees ex Fear duds rade 0 2 0 3 Electrical Connection een tea 0 3 0 4 Emergeney Stop CircUlt 2 dae En tip aa Mine bea es pe 0 3 URCNEGO T ITCRUM 0 4 0 6 WOrkplaGes nitri taies aei der Ue Een tb 2a den tea iU cu rae cire tedet 2a bea Poe LU cu Eu 0 4 0 7 Equipment for Personal Protection seres asie a Aae a E E ene mener 0 4 0 8 Sound Pressure Level tirer e pate er EE Eder ERES Desa E des ERES 0 4 eR MEN DiSPOSal POE 0 4 OM AMECUII I Gw 0 5 0 10 1 Covers 0 5 0 10 2 WarhingASIgns x eet uomen tee RT E RERO EAA TET 0 5 0 11 Emergencies Fire Exting
29. ernal ye C 16 circuit 33 Circuit protective element CCP2E25 L 17 OUT 8 F 34 24V Page 1 9 DS Controller DS 1 4 3 Interface List Specifications for the I O Connector during program mode and position mode are different The interface list for each is indicated in the table below Position Mode I O Connector 34 Pin Cable Colour zb w Distribution Voltage 0 V orange red A 18 dE ELSE Sa 20 a BEER Kae MEER 9 E E tum BEIN BEE 46 HEU BET EHE NC orange blue A Lo NC gmyrdA po NC grey A po NC whiefedA NC p svwhieblueA L NC ellos A Reserve yellowibueA CPURESET pinMedA _ O 00 Start Input Position pinkblueA m NC orangeblueB O 08 NC geyedB 04 PositionNo IImputt grey blueB 00 PositionNo 4Inpu whit bleB 09 Position No 20Iput pinkrdB p N S CA EN Oo p LIFLSI LS oo Position No 200 Input grey red C Position No 400 Input NC whit redC o2 o r2 Alarm Output white blue C o2 AJO Ready Output yellow red C Positioning Complete Output yellow blue C NC NC NC NC NC NC NC NC W N pink red C po NC pink blue C Po NC orange redD Output m jv N 6 33 1 34 av orange blue D grey red D Distribution Voltage 24 V Input grey blue D
30. ge 2 6 DS Slider Type DS 2 3 3 Lubrication When the grease contains dust becomes dull in colour or begins to wear away through extended use lubricate the actuator using the procedure below 1 How to lubricate To lubricate the ballscrew apply grease to the screw with your finger then spread it out by moving the slider back and forth To lubricate the guide apply grease with your finger then spread it out by moving the slider back and forth wi gt 2 What grease to use IAI uses lithium grease N o 2 There are other brands of grease commercially available for the ballscrew and slider These are acceptable as long as they are a lithium type grease Note Never use a fluorine based grease Mixing this with a lithium grease produces a chemical reaction which damages the actuator Page 2 7 DS Slider Type DS 3 Replacing the cover c TRAD M Inside the slider cover is a spring that allows it to follow s a T along the dust shield Lift the shield up from the bottom hi Y and attach the side cover T4 If the shield is not straight move the slider slightly to straighten out the shield Or lift the shield gently to straighten it out Tighten the bolts on the side cover The torque should be for a small plus screw 0 6Nm 6 kgcm After completing the inspection replace the cover Page 2 8 DS Slider Type DS 2 3 4 Checking the Dust Shield The dust shield is made from stainless stee
31. he Dist Shield is ettet et e dede eredi 2 9 ERIGI HE 3 1 1 IUBE 3 1 2 Operating Environment m s des 32 MMStAllAtiON E 3 2 1 ROIA K 1AE MT Rt 3 2 2 Attaching the Workpiece iste ain iii ela o E hahsiouigonninsn 3 3 3 2 3 Wiring Cablez etr ehem died AEAEE Eaa E T A oR etes ede dto E Eia DANEAS Si 3 3 3 2 4 Adjusting the Home Positiones au nn A ene eene a eE E devine e a ae ar EEE EER 3 3 3 2 5 Changing the Motor Positiot ser a ERR In E AEA A 3 3 3 3 Mantena eia a a a u E en en EAO 3 5 3 3 1 MaintenanceSchedule e aea A SOn E rA P perte bee ee et RR eran 3 5 3 3 2 Cleaning the ExterioF see RI EE E ERRANT NN REESE REN ERN SERRE RER TENEAT 3 5 3 3 3 Inspection tlie Anterior iiit deae RERO en 3 6 3 3 4 EU II m 3 7 3 3 5 Inspection and Replacing the Timing Belt eese eerte nennen 3 8 3 3 6 Inspecting and Adjusting the Brake esee teret tette tene netten tenen 3 10 4 DATA OF THE DS SERIES SPECIFICATIONS 4 1 4 1 Specifications for the Slider Type 2uu0uuu0anaanannnnnnununnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnn 4 1 1 High Speed Type DS 85H sees nie guniunsaklashn sen NENA 4 1 2 Medium Speed Type DS S5M 4 1 3 Low Speed Hugh Thrust Type DS S5L ie m 4 1 4 Low Speed Hugh Thrust Type DS S4H esee tette tene eene 4 1 5 Medium Speed Type DS S4M uuuessssnsesusnsnsnsnnnnnnnnnnnnnsnnnnnnnnnnnsnnonnsnnnsnsnnnsnnsns
32. ill not run properly in this condition Page 1 31 DS Slider Type DS 2 DS Slider Type 2 1 Part Names and function 2 1 4 Part Names Dust shield mounting bolt Front cover Slide cover Dust shield Slider Dust shield mounting bolt Slide cover Slide cover Motor housing mounting bolt Encoder cover Slide cover Slide cover mounting bolt Please note the following when handling the actuator e To handle the actuator support it from underneath or grasp the area around the side cover mounting bolts e Do not place excessive load on the cable e Do not place heavy loads on the encoder cover slider cover or other plastic parts 2 1 2 Operating Environment Install the actuator in a place where the operator can work without a protective gear See the table bdow for specific operating environment criteria Operating Conditions Ambient temperature 0 50 C Relative humidity 35 95 non condensing Avoid direct sunlight 6 Mimaldut O y 8 Avoid strong electromagnetic waves ultraviolet rays and radiation Page 2 1 DS Slider Type DS 2 2 Installation 2 2 1 Installing the Actuator Mount the actuator to a machined surface or one of comparable precision Install the actuator as shown below The actuator base and lower surface are parallel to the guide When travelling precision is required use this surface as a reference to mount the actuator For basic mounting use the four m
33. imum Thrust 1 Payload 2 3 Moment 2 4 yur uonsoyddsy Thrust direction Page 4 10 65 7 Vertical 2 kg 5 000 km life expectancy Ma 4 5 Mb 5 4 Mc 4 1 Thrust direction Data of the DS Series Specifications DS At a speed of 10 mm sec for 5 seconds Even load distribution on the slider Fix base securely to a flat strong frame For horizontal use load should be applied in the thrust direction as shown in the drawing If the slider becomes deformed it will cause poor movement At an acceleration of 0 2 G and a speed of 400 mm sec Direction of load moment is Ma 4 2 2 Low Speed High Thrust Type DS ASL w 20 200 0 02 pos AC Servo Miniter Signals Encod Togeth ith th t th indl ncoder ogether wi e motor on the spindle APs FE A B Z phase Voltage output BPhase T Cog b ZPhse J LH Input voltage 5V Homing pulse 1 pulse 1 rotation uojjeoypeds Specification Dry single head on when deenergized electromagnetic brake Single brake torque Nm Integrated with base DS dedicated Timing belt Reduction ratio 1 2 Hardened alloyed Steel Extruded aluminium A6NO1S T5 White alumite treated Extruded aluminium A6063S T5 White alumite treated Aluminium die cast baked finish Polyacetal plastic 11 conductor composite cable 5m standard length Grease Ballscrew Lithium type grease jueupduo UEN jo eioruis Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Maximum Thrust
34. isual check of the interior to see if there is any dust or foreign matter in the unit and check the lubrication Even if the grease you see around the parts is brown the lubrication is fine as long as the travelling surfaces appear shiny Page 3 6 DS Arm Type DS 3 3 4 Lubrication When the grease contains dust becomes dull in colour or begins to wear away through extended use lubricate the actuator using the procedure below 1 How to lubricate To lubricate the ballscrew apply grease to the screw with your finger then spread it out by moving the slider back and forth Apply grease here To lubricate the guide remove the return cover attached to the guide block and apply grease directly on the bearing 2 What grease to use IAI uses lithium grease No 2 There are other brands of grease commercially available for the ball screw and slider These are acceptable as long as they area lithium type grease Note Never use a fluorine based grease Mixing this with a lithium grease produces a chemical reaction which damages the actuator Page 3 7 DS Arm Type DS 3 3 5 Inspection and Replacing the Timing Belt 1 Removing the belt cover Timing belt Actuator Remove the pulley cover as shown at left and inspect the timing belt 2 Inspection the timing belt The durability of the timing belt is largely dependent on the operating conditions It is difficult to give an absolute rule regarding when to replac
35. ith MAx25 bolts Reattach the pulley cover Changing the motor position will affect the home position so always make sure to readjust home For a ball screw lead of 6 mm home will move 1 5 mm for every 90 change Page 3 4 DS Arm Type 3 3 Maintenance 3 3 1 Maintenance Schedule Perform maintenance work according to the schedule below Visual Internal Lubrication Inspection Check Start of operation After 1 month of operation After 1 year of operation Semiannually thereafter Note 1 The above schedule assumes running time is 8 hours per day When running time is high such as continuous day and night operation shorten the maintenance intervals as required Note 2 The end cover supports the ballscrew so please do not remove it Do not remove the encoder cover as this contains precision equipment 3 3 2 Cleaning the Exterior 1 Wipe off dirt with a soft cloth 2 Do not use strong compressed air on the actuator as this may force dust does into the crevices 3 Do not use petroleum based solvents on plastic parts or painted surfaces 4 If the unit is badly soiled apply a neutral detergent or alcohol to a soft cloth and wipe lightly Page 3 5 DS DS Arm Type DS 3 3 3 Inspection the Interior 1 Remove the cover Turn the power OFF Using a 1 5mm hexagonal wrench remove the cover as shown in the picture and visually inspect the interior 2 Visual check of the interior Make a v
36. l and is adjusted at the time of shipment If the shield slackens with use make the following adjustments Move the slider to the end Loosen the screw at the front end with a 1 5mm wrench Pull the shield just enough to make it taut Move the slider manually to make sure it moves easily If there is resistance in the movement there is too much tension in the shield Page 2 9 DS Arm Type DS 3 DS Arm Type 3 1 General 3 1 1 Part Names Motor bracket Pulley cover Screw cover mounting screws Screw cover Motor housing Encoder cover Please note the following when handling the actuator Support the base when handling the actuator e Do not place excessive load on the cable e Do not place heavy loads on the pulley cover encoder cover or other plastic parts 3 1 2 Operating Environment Install the actuator in a place where the operator can work without protective gear Specific criteria for the operating environment are shown in the table below Avoid exposure to water cutting oil and other liquids 5 Avoid exposure to corrosive or combustible gas 6 Minimaldust Do not subject to vibrations or shock greater than 0 5 g Page 3 1 DS Arm Type DS l8 Avoid strong electromagnetic waves ultraviolet rays and radiation 3 2 Installation 3 2 1 Installing the Actuator Mount the actuator to a machined surface or one of comparable precision The DS aduator has a built in brake Conn
37. ld all cables and wires from electromagnetic noise 1 6 2 POWER Source Power supply is DC 24V 1 6 3 Noice Supression This section explains noise suppression measures when using the controller 1 For grounding please use a dedicated ground of Class 3 or better The thickness of the cable should be 2 0 5 5 mm or larger DS Controller DS Controller Device Class 3 ground Correct Avoid this method Other Device Page 1 15 DS Controller DS 2 Separatethe wiring systems for the controller power and for other devices AC230 V Other Circuits Controller Power DC24V External Power Other Devices Controller Power External I OPower DS Controller 3 Wiring Notes Twist the cable for the DC 24 V external power Isolate the controller cable from high power lines such as motor circuits Do not bundle and do not place in the same piping circuit Thecontroller encoder cable is particularly sensitive to noise so make sure to keep it separate from load wiring for other equipment Page 1 16 DS Controller DS 4 Noise Source and Noise Suppression Noise comes from many sources but the most immediate when building a system are solenoid valves magnetic switches and relays Noise from the devices can be prevented by taking the following steps AC solenoid valve magnetic switch relay Install a surge absorber parallel to the reactance load solenoid and r
38. n Firmware Update Software update via floppy disk Page 1 7 DS Controller DS 1 4 2 External I O Specification External Input Circuit External Power Voltage 24 V DC 10 aav ON OFF Voltage e ON voltage min 18 0 V DC e OFF voltage max 6 0 V DC External Connection Device No voltage contact point minimum load about 5 V DC 1mA Photoelectric proximity sensor type PNP PLC Transistor output type PNP open collector PLC Contact point output minimum load about 5 V DC 1mA Note When a no contact circuit is connected to an external circuit make sure that the leakage current is under ImA when the switch is OFF or it could cause faulty operation External Output Circuit Leakage Current Max 0 1 mA External Connection Device Miniature relay e PLC input unit type PNP Application for TD62084 Notes e For all of the external outputs the flywheel diode D is connected on the inside e Take care when connecting because if the load short circuits or the current exceeds the maximum load current this will cause a failure in the output circuit Page 1 8 DS Controller DS External I O Circuit Circuit protective element L CCP2E25 N 33K9 ra 18 IN 1 Internal circuit 20 21 22 24 25 23 26 10 27 11 28 12 29 V R 13 IN Q4 w 30 OUT 1 14 31 15 32 Int
39. n of the workpiece to the measurements below to prevent interference between the screw cover and workpiece DS A5 A 65 mm Slider DS A4 A 53 mm SN n 3 2 3 Wiring Cable The actuator cable is resistant to bending fatigue but it is not robot cable so avoid housing the cable in movable wire duct with a small radius In an application where the cable cannot be properly anchored try to place the cable so that it sags only under its own weight or use self standing type cable hose as large radial wire duct to limit the load on the cable 3 2 4 Adjusting the Home Position After installing the actuator perform the homing operation to confirm home Home direction can be changed with the parameters If you allow a large offset amount the moving range is limited by that amount If you specify an offset amount greater than Imm you will have to reset the software limit and reduce the stroke by that amount Note To change the home offset amount requires the optional PC software By changing the homing direction please contact the technical office of IAI 3 2 5 Changing the Motor Position You can change the position of the motor for greater flexibility when installing the actuator Page 3 3 DS Arm Type DS 1 Remove the pulley cover 1 Remove the four bolts M4x25 used to mount the motor bracket 1 While pushing the motor bracket lightly against the actuator rotate it and set the position 1 Reattach the motor bracket w
40. nals for the ENABLE SW it is necessary to connect these when the servo is ON Page 1 12 DS Controller DS e TEACHING RS232 PORT SW PORTSW ON The teaching pendant or RS232 communication lines can be used PORTSW OFF The connector function stops The pin numbers 12 and 13 EMG SW and the pin numbers 18 and 19 ENABLE SW are shorted internally 1 4 5 Port Encoder es es END BE A IGey o o o ic EHE Cc Red w w NI N Page 1 13 DS Controller DS 1 5 Dimensions Page 1 14 DS Controller DS 1 6 Installation Environment and Noise Measures 1 6 1 Installation Environment 1 Do NOT block the air vents of your controller during installation and wiring Not only will insufficient ventillation prevent optimal performance but it may lead to a malfunction in the controller Your DS Controller is NOT dust water or oil proof Take steps to prevent foreign matter from getting into the controller air vents Avoid using your controller in environments subject to contamination by dust oil mist or cutting oil Do not expose your controller to direct sunlight or place it near a heat source The controller should be used in an environment where the ambient temperature is 0 C 50 C humidity 95 96 or less no condensation and is free of corrosive or inflammable gases Avoid external vibration unnecessary impact or excessive shocks to your controller Take steps to shie
41. ngth Page 4 12 Data of the DS Series Specifications DS Grease Ballscrew Lithium type grease p Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Vertical 2 5 kg Moment 2 4 Nm 5 000 km life expectancy At a speed of 10 mm sec for 5 seconds Even load distribution on the slider Fix base securely to a flat strong frame For horizontal use load should be applied in the thrust direction as shown in the drawing If the slider becomes deformed it will cause poor movement At an acceleration of 0 2 G and a speed of 330 mm sec Direction of load moment is Ma 4 7 Page 4 13 Data of the DS Series Specifications DS 4 2 4 Low Speed High Thrust Type DS A4L Rated Output 20 Rated Speed 165 Rated Thrust Repeatability 0 02 AC Servo Mgjg uojjesypeds Encoder Together with the motor on the spindle dl A Phase j l f A B Z phase Voltage output BPhase I LJ L ZPhse J4 LH Input voltage 5V Homing pulse 1 pulse V rotation Brake Specification Dry single head on when deenergized electromagnetic brake M33 Holding torque N 122 5 Single brake torque Nm 0 098 Ballscrew axis 24 V DC 8 mm Lead 5 mm Rolled thread C10 Backlash 0 1 mm or less Integrated with base DS dedicated Timing belt Reduction ratio 1 2 Hardened alloyed Steel Extruded aluminium A6NO1S T5 White alumite treated Extruded aluminium A6063S T5 White alumite treated Aluminium die cast baked finish Polyacetal plastic I 1 condu
42. nsnsnsosnsssnsasnnnsann 4 1 6 Low Speed High Thrust Type DS SAL nsenssesesssssenensnsnenenenenenenensnnnenensnenenenenenenenenenenenenenennn 4 2 Specifications for the Arm Type unsnnnsennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn rare 4 2 1 Medium Speed Type DS A5M zeenenenenenenenenensnenenensnenenensnonenensnenenensnenenonsnenensnsnonsnonenensnsnenensnenenenensnenensnsnen 4 2 2 Low Speed High Thrust Type DS A5L 4 2 3 Medium Speed Type DS AAM sss een a 4 2 4 Low Speed High Thrust Type DS AAL unnseensnesnsnssnsnsnsnsnensnnnsnnnensnsnnennnnnenensnssennnsnsnssnnn 5 PARAMETER 5 1 Safety DS 0 Safety The DS Positioning system has been designed and constructed in accord with the EC Machinery Directive Residual risk Misuse or improper operation can lead to severe injury as well as damage to property or the environment Observe warnings and safety notes Only adequately qualified personnel must operate the DS Positioning S ystem WARNING Each operator must have read and understood these operating instructions 0 1 Classification of Safety Notes Warnings and Notes in this operating manual are identified by a symbol with keyword printed in the page margin The warnings and notes appear in bold type and are highlighted by a frame These warnings are hierarchically classified The keyword WARNING is used for warnings from imminent hazards Possible consequences may be death or severe
43. o use equipment for personal protection 0 8 Sound Pressure Level The A weighted equivalent sound pressure level of the DS Positioning System is below 70 dB A 0 9 Disposal Decommissioning Electrical waste components monitor etc may pollute the environment Properly dispose of the DS Positioning System ATTENTION Page 0 4 Safety DS 0 10 Guards The DS Positioning System is equipped with covers e warning signs 0 10 1 Covers The covers e prevent you from touching live components e prevent foreign bodies from entering and provide electromagnetic shielding The covers must be removed only temporarily and only by authorized persons for maintenance work 0 10 2 Warning Signs Warning signs on the DS Positioning System alert to risidual risk Warning of hazardous electrical voltage DS Control DS Drive 0 11 Emergencies Fire Extinguishing Equipment In case of emergency switch off power supply to the DS Positioning System If the DS Positioning System is on fire extinguish it with an ABC type powder extinguisher or with carbon dioxide lf you use water be sure to stay at the required minimum distance The minimum distance among other factors depends on nozzle diameter spraying angle or full beam If a C size hose is used with nozzle 12 mm and spraying beam the minimum distance is one metre Page 0 5 DS Controller DS 1 DS Controller 1 1 Safety Precautions This product wa
44. ounting holes located on the upper surface of the actuator Rest the actuator on the mounting surface and check to see that a O lmm thickness gauge cannot be inserted at the four mounting holes If the bolts go in a steel surface with tapped holes then use hexagon sockets with length shown in 1 and if the surface is a light metal use the length in 2 Page 2 2 DS Slider Type DS If the actuator has an overhang you can use the two mounting holes at the motor end and the tapped holes on the underside of the base but please make note of the following e The depth of the tapped hole is 5mm Select a bolt with an engagement length of greater than 3mm and less than 5mm and adjust the washer length if necessary The flatness of the mounting surface should be more precise than for basic mounting If the level of the flatness is poor when the overhang is mounted the actuator could warp and cause travelling impedence Corrct the flatness if the slider motion slows at the home end or generates noise since ths will reduce the life of the actuator 2 2 2 Attaching the Workpiece Use the four tapped holes at the top of the slider to attach the workpiece To attach the workpiece select bolts that will have the engagement lengths indicated in the table below and adjust the length of the washer if necessary Also make sure that the workpiece does not touch the slider cover Slider Mounting Area Engagement Length
45. s Actuator 4 Timing for Position No Switching Position 1 Position 2 Input A Position 1 execution A lB start B E B Position 2 execution External Start Kd Input P End ER Moving md Moving Output The timing for the position number shifting is the time from after the position presently being executed is completed until the next external start input start signal can be input Page 1 28 DS Controller DS 5 Timing of Motion Using the Hold Signal Position Input Actuator movement PE Slowing to a stop Movement start The servo actuator is slowed to a stop by turning the hold signal ON while the actuator is moving and starts up again by turning the hold signal OFF 6 Movement in Random Sequence To move the actuator in a random order select the position number and input external start signal for each movement Select Position Number Pose Rem Vae Train ROMS ze RA 0 3 m GM 150 000 External Start Input Lv m ELLE a Movement Complete P End ON 0 3 380 000 EI 200 000 Page 1 29 DS Controller DS 1 9 Error Code list When an error occurs the alarm LED red colour on the controller s front side will light up At the same time the I 0 alarm output will turn ON and the READY output will turn OFF Error Code list External Interrupt Error 1 Motor over current 2 Over regenerative current over negative load 3 Driver overheat Mo
46. s developed as components for driving automated equipment and is designed not to produce greater torquing or speed than is necessary However strictly observe the following items to prevent any accidents from occurring 1 As arule any handling or operating methods not described in this manual should be viewed as things that should not be attempted Please contact the company if any portion of the contents of this manual are unclear 2 Use only the products specified for wiring between the actuator and controller 3 Stand clear of the operating range of the machine when it is in motion or is ready to operate Surround the system with safety partitions if there is a possibility that people can enter the area where the machine is being used 4 When assembling adjusting or performing maintenance on the machine always disengage the power supply to the controller During work display a sign stating work in progress where it is readily visible Also keep the power cable close to the operator so that another person cannot inadvertently switch on the power 5 When more than one person is working on the system agree on signals beforehand to ensure everyone s safety before beginning work In particular when doing work involving axis movement always call out for everyone s safety regardless of whether power is ON or OFF or the axis is to be mechanically driven or manually moved 6 When the user needs to lengthen the cables check the wiring
47. st injury injury to people WARNING Possible consequences may be death severe or moderate injury injury to people damage of property or the environment ATTENTION The keyword NOTE is used for user hints The possible consequence of failure to comply may be damage to property e g at the DS Positioning System NOTE Page 0 1 Safety DS 0 2 Intended Use The DS Positioning System is exclusively designed and constructed to position an DS Drive either e in slider version or e inarm version Danger due to misuse of the DS Positioning System The consequences of unintended use may be injury to users or other people as well as damage to the DS Positioning System or environmental pollution Only use the DS Positioning System as intended Observe the warnings ATTENTION Unintended Use The DS Positioning System must not be used in explosive atmospheres Limit Values e Humidity max 95 relative humidity non condensing e Storage temperature min 20 C max 85 C e Operating temperature min 0 C ma 50 C e Height above sea level max 1000 m above sea level e Enclosure type IP 54 according to EN 60529 must be achieved by environment integration The DS Positioning System has been designed and constructed to operate safely Hazards from Changes or Supplementation Do not make unauthorized changes Do not supplement equipment components or devices of other manufacturers before you have con
48. tacted IAI Industrieroboter GmbH especially concerning the suitability of these parts ATTENTION Page 0 2 Safety DS The DS Positioning System requires little maintenance but is not entirely maintenance free Irregular Maintenance The consequences of irregular maintenance may be damage to the DS Positioning System and production downtime Observe the following maintenance notes NOTE 0 3 Electrical Connection The DS Positioning System must be connected to electrical mains see Chapter Installation Electrical mains voltage presents a considerable hazard Consequences may be death or severest injury or damage to property The connection to the electrical mains must be made by a qualified electrician On the primary side suitable fusing must be provided for ATTENTION Power Supply DC 24 V 10 96 0 4 Emergency Stop Circuit As defined in the General safety requirements each machine must be equipped with command devices for safe stoppage When the machine has stopped the energy supply to the drive system must be interrupted The DS Positioning System is designed for integration into machinery plant Depending on the risk assessment made by the manufacturer of the plant a circuit for safe stoppage of the plant must be realized This applies to normal stoppage and to stoppage in case of emergency In plants with linked machinery all preceding and or following equipment must be stopped safely if its continued opera
49. tea N eip the attached object is 1 2 the At a speed of 10mm sec for 5 seconds jur uopsoldd load moment Fix base securely to a flat strong frame 1 Atan acceleration of 0 2 G and a speed of 165 mm sec Mb direction 1 Direction of load moment is Mc L we WITZ ge 7 8 GE el Ma direction Page 4 8 Data of the DS Series Specifications Page 4 9 DS Data of the DS Series Specifications 42 Specifications for the Arm Type 4 2 1 Medium Speed Type DS A5M Model DS A5M Rated Output Rated Speed uonEypeds Repeatability 50 50 DS 20 400 Rated Thrust ae SEE 0 02 AC Servo Motor Encoder Together with the motor on the spindle A B Z phase Voltage output Input voltage 5V Specification Holding torque N Slider Hardened alloyed Steel weuodwong UEN jo einioruis APhase 71 71 BPhase LJ L ZPhse J LWW Homing pulse 1 pulse V rotation Dry single head on when deenergized electromagnetic brake ass Single brake torque Nm 0 098 Timing belt Reduction ratio 1 2 Base Extruded aluminium A6NOIS T5 White alumite treated Side Cover Extruded aluminium A6063S T5 White alumite treated Motor Housing Aluminium die cast baked finish Encoder Cover Pulley Cover Polyacetal plastic Motor Cable 11 conductor composite cable 5 m standard length Grease Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 Max
50. tion could present a hazard Not safely stopped DS Positioning System People may be injured by the DS Positioning System if it is not stopped safely Realize a circuit ensuring that the DS Positioning System is stopped safely both in normal operation and emergencies ATTENTION Page 0 3 Safety DS 0 5 Operators The DS Positioning System must be operated exclusively by authorized persons The operating manual must be available to operators Adherence to Safety Notes The consequences of improper operation may be severe or moderate injury injury of people damage to property or the environment Do not operate the DS Positioning System before you have read and understood the entire operating manual and especially the Chapter Safety ATTENTION Maintenance Work The maintenance personnel may be seriously injured if the DS Positioning System is not properly shut down Switch power supply to the DS Positioning System off Secure it from restart Maintenance work must be carried out by qualified personnel only ATTENTION 0 6 Workplaces The DS Positioning System has two workplaces Operate the control unit e from the programming station with the PC programming system or e from the machine operating panel for instance with the Start button in Automatic operation 0 7 Equipment for Personal Protection Depending on the kind of positioning job the workpiece to be handled or the tools used it may be necessary t
51. tion range 24 V DC 10 e Check the controller vents and clean any accumulated dirt or dust e Check the controller cable controller axis and make sure that there are no loose screws or disconnections e Check for loose controller mounting screws Tighten if necessary e Check each cable axis cables general I O cables system I O cables power supply cable Check for loose connections damage or excessive wear Replace if necessary 2 Recommended Spare Parts Should a breakdown occur even if it is discovered early repairs cannot be done if there are no spare parts It is advisable to keep a small supply of spare parts especially for those parts that wear down with use The following spare parts are recommended e Cables e Batteries Ni Cd batteries have a general shelf life of about 6 years but this varies depending on use conditions and environment 3 Memory Backup When the the controller is fully charged the backup memory is guaranteed for 3 months In actuality the backup memory is not erased for 6 8 months But if the controller is to be left for a long period more than 3 months without having current run through it please take precautions to save your program position data and parameters To fully charge the controller if it does not contain any data you will need to leave the controller with the power ON for 3 days If the memory is erased the system s preset parameters will be set but the actuator w
52. tomatically immediately after the controller is reset which may startle the operator To ensure safety always use an interlock at the start of a program such as having the actuator operate after receiving a confirmation signal As always please take safety precautions when using an auto start program Page 1 23 DS Controller DS Operation Based on the External Start Signal Selection 1 Program Operation Connect the controller to the External Device external devices using the program mode Controller J Ready Output READY signal ON gt gt When the READY signal turns confirmed ON the READY lamp green on the controller front panel V Y lights up I O Processing Program No input i Program No Program No command l Y External start 4 input Start signal confirmed lt A Y Eee 7 When the program is executed 3 N the number of that program Program operation EMG signal ON shows up in the CODE display The program number from the external device is input as a BCD code Start signal ON Start signal from the external device is input EMG n on the controller front panel input d E When an emergency stop N ENG te e EMG signal ON signal from the extrenal device confirmed is input or if the controller N malfunctions the controller Y c tums the servo OFF READY abnormal A lamp turns OFF S Servo OFF
53. tor Overload Error Mechanical oveload of motor Motor is unable to perform properly due to mechanical ovedoad Software Limit Error Exceeded software limit AS Pole Sense Error Unable to sense pole BGE CC CORN B6 Undefined TAG Number TAG number is not defined B9 DO EDDO Pair Error DO and EDDO are not the same quantity o o Arch Trigger was set outside the range of 50 100 DO AccelemtionEror Acceleration exceeds limits D6 Axis Over Error Appointing of more than two axis for circular circular are motion D8 Position Number Error Position number exceeds the limit D9 PointNumberEror Negative number was input in the point number DB Variable Error Variable is not assigned correctly 000 DD Divisin 0 Emor Result of the divisionis 07T Page 1 30 DS Controller DS Note An E appears at the head of the error code followed by 2 digits Error Code xx 1 10 Maintenance To ensure safe and trouble free operation of your system a regular maintenance and inspection program should be implemented Be sure to turn OFF the power before initiating any maintenance or inspection work An inspection is recommended at least once every 6 to 12 months However depending on the environment a more frequent inspection schedule may be advisable 1 Inspection Guidelines e Check and make sure that the power supply to your controller is within the specifica
54. ual Check for loose Check interior Lubrication inspection dust shield Start of ee I a 1 month of operation After 6 months of operation After 1 year of operation Seminually thereafter Annually thereafter Note 1 The above schedule assumes running time is 8 hours per day When running time is high such as continuous day and night operation shorten the maintenance intervals as required Note 2 The end cover supports the ballscrew so please do not remove it Do not remove the encoder cover as this contains precision equipment 2 3 2 Cleaning the Exterior 1 Wipe off dirt with a soft cloth 2 Wipe the dust shield gently so that it does not bend 3 Do not use strong compressed air on the actuator as this may force dust does into the crevices 4 Do not use petroleum based solvents on plastic parts or painted surfaces 5 If the unit is badly soiled apply a neutral detergent or alcohol to a soft cloth and wipe lightly Page 2 5 DS Slider Type DS 6 Inspecting the Interior 1 Removing the cover Turn the power OFF Using a 1 5mm hexagonal wrench remove the cover as shown in the picture and visually inspect the interior 2 Visual check ot the interior Make a visual check of the interior to see if there is any dust or foreign matter in the unit and check the lubrication Even if the grease you see around the parts is brown the lubrication is fine as long as the travelling surfaces appear shiny Pa
55. uishing Equipment see 0 5 1 DS CONTROLLER 1 1 TT S8afety Pr cautioris eere t vei e rete ta Uie v EPOR NES Erbe d ER 1 1 1 2 Warranty Period and Scope of Warranty ssssssssssseeee mee 1 2 1 3 Fan Names and Functions ines enhn Er ERR A ax Ee EREEE ER RR RR E nein 1 3 1 3 1 Part Names 1 3 1 3 2 FUNCTIONS oie hen ee A Sh ee ee ee al atin the ee ek a Nie NU te eho oa date ES 1 4 1 3 3 Explanation of the Code Displays eese tenete tenete tette netten tenente 1 6 124 SpecifICatiOri aire bt DOR URN NOMINUM IU RARNREEN REX MR UE REIR EROERIEIE 1 7 1 4 1 Controller Specification m seen nennen spinnen en Nasen ep Eee eh 1 7 1 4 2 External L O Specification ede od M D ERR NER FURIA Guess 1 8 1 4 3 Interface Lista cca eint ea ER ha OR eR e ec n at Ee 1 10 1 4 4 TEACHING RS232PORT e easier eeu eti RR e MH rate erre eie eret 1 12 1 4 5 Port Sum 1 13 1 5 Dimensions uses 1 14 1 6 Installation Environment and Noise Measures ssssesee ee 1 15 1 6 1 Installation Environment eese essent tente a rA E tnter AE ES sarae tenente rennes 1 15 1 6 2 POWER Source nase 1 15 1 6 3 NoiceSupression i een OE einen UE UE HERR EROR RAM gates 1 15 TF GONNECIHONS e c JC 1 19
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