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1. E E A R 49 24 Adjusting the Home Position esse een vp HR e e ee eee He eee re et pe teer edet 40 25 Changing the Motor Posion sissien oain eoe a e ENE IEE IE E s Noine E E NE ESIE s 49 3 Maintenance 50 55 341 Mamtenance Schedule ve Sete n ats 50 32 Cleanings the Exterior OS eI ea INS ER a 50 3 3 Inspecting the INter Of v e oce err eoe te bte to ere eee Deo bcn ete ipe e tee etiem e leute eds 50 SA Lubrication 51 35 Inspecting and Replacing the Timing 52 36 Inspecting and Adjusting the 54 Part IV DS Actuator Specifications ereesssvessrveensvnensvvenssneensnvesssvenssnenssnesnnnennnnessnnsesnnsnsnsenenseserrr 96 65 1 Specifications for the Slider Type sessvssvssversevnsvnnennenneensensennesnessvensennesnsennennenneensennennessennsensesnsvsnnenseenneeneenneensesnesnneenee 56 64 1 1 High speed type DS SAOH inne mene eO Ob RE Tp e e isteres 56 12 Medium speed type DS SAOM eni i e re e ree b i d 57 13 Low speed high thrust type DS SAGL 58 14 High speed type DSSASH jan tente 59 15 Medium speed type DS SASM spa knee este 60 L6 Lowspeed hish thr st type DS SASL 4c eie ete p ere PORE eee teg 61 17 High speed type DSSAMH PRO I RUE ON PET UU 62 18 Medium speed type DS SAIM tene Rete eire tee e e rikinge
2. dl Model DS SA6L 50 100 150 200 250 300 350 400 450 500 550 600 Stroke mm 50 100 150 200 250 300 350 400 450 500 550 600 g Rated Output W 30 S Rated Speed mm sec 200 190 160 135 S Rated Thrust N kgf 96 8 9 8 i Repeatability mm 0 02 Unit Weight kg 1 3 1 5 1 7 1 9 2 1 2 3 2 5 2 7 2 9 3 1 3 3 3 5 Motor AC Servo Motor AC motor attached 192P R Signal wave A B Z Phase APhase LT L Encoder Input voltage 5 BPhase I LT L C Phase Sie ee Homing pulse 1 pulse 1 rotation g S S 9 Ballscrew 10mm Lead 3mm Rolled thread C10 Backlash 0 1mm or less Guide Direct recirculating ball bearing Hardened carbon steel ground track 5 Motor Ballscrew 9 Connection Integrated motor axis and ballscrew axis 3 Base Exclusive extruded aluminum A6NO15S T5 equivalent White alumite treated 9 Slider Special steel alloy 5 Side Cover Exclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease rease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SA6L 50 100 150 200 250 300 350 400 450
3. parameter setting Enter the number of the program to be automatically Set Automatic Start Program No 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 Reset the Controller occurs or by turning the power OFF then ON again After resetting the controller the program number that was Automatic Program Start entered automatically starts Precautions when using an auto start program The servo actuator will start automatically 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 To start simultaneous multiple programming set all other programs into EXPG command placing them ahead of the main auto program As always please take safety precautions when using an auto start program Page 26 8 Moving the Actuator DS Controller Operation Based on the External Start Signal Selection 1 Program Operation Connect the controller to the Controller External Device external devices using the program mode Power ON C Power ON gt R C READY signal O When the READY signal turns ON the READY lamp green on the controller front panel lights up Processing Program
4. 3 1 Part Names LED display Code display Controller CODE READY ALARM BAT KE BRA RELEASE BAU R NORMAL Function switch Brake release switch TEACHING 232 PORT TEACHING RS232 PORT connector PORT switch IAI Corporation Brake connector External or use device connector Motor encoder connector Power and emerg terminal block Ground terminal block Page 6 3 Part Names and Functions DS Controller 3 2 Functions CODE display This is a 3 digit display device that indicates the operating status of the controller LED display READY This indicates that the controller is ready to be operated ALARM This is the display when there is a malfunction in the equipment BAT This indicates battery voltage is low Brake release switch RELEASE The brake is released NORMAL The brake is ON This is the normal setting The brake release switch is enabled durng the servo free state indicated below 1 From the time the power is turned ON until the homing command is given 2 When Svof is selected during direct teaching 3 When an alarm occurs PORT switch 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 TEACH Function switch TEACHING RS232 PORT connector ING RS232PORT connector is not
5. INTELLIGENT ACTUATOR Dynamic Series Actuator amp Controller Operating Manual Intelligent Actuator Inc 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 For Central and East Coast Time Zones please call our Itasca IL office at 1 800 944 0333 or FAX630 467 9912 For Mountain and Pacific Time Zones please call our Torrance CA office at 1 800 736 1712 or FAX 310 891 0815 Monday thru Friday from 8 30AM to 5 00PM INTELLIGENT ACTUATOR Intelligent Actuator Inc U S Headquarters 2690 W 237th Street Torrance CA 90505 310 891 6015 310 891 0815 FAX Intelligent Actuator Inc Midwest Regional Office 1261 Hamilton Parkway Itasca IL 60143 630 467 9900 630 467 9912 FAX www intelligentactuator com January 1998 Intelligent Actuator Inc 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 Intelligent Actuator Inc Disclaimer The information and technical data contained herein are subject to change without notice Intelligent Actuator Inc assumes no responsibility for any errors or omissions regarding the accuracy of the information contained in this publication Table of Contents DS Part D DS
6. vi Encoder BPhas L L ZPhse J U E Homing pulse 1 pulse 72 rotation z Specifications Dry single head on when deenergized electromagnetic brake Model MB33 g Brake Holding torque N kgf 51 0 5 2 ER 0 098 1 0 E Mounting position Ballscrew axis 2 Rated voltage DC24V Ballscrew 10mm Lead 12mm Rolled thread C10 Backlash 0 1mm or less Guide Integrated with base DS dedicated Timing belt Reduction ratio 72 Connection Slider Hardened alloyed steel Base Extruded aluminum A6N01S T5 White alumite treated Side Cover Extruded aluminum A6063S T5 White alumite treated Motor Housing Aluminum die cast Baked finish Encoder Cover Pulley Polyacetal plastic nur uoneorddy Cover Cable 11 conductor composite cable 5m standard length COS Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Maximum Thrust 1 N kgf 65 7 6 7 Payload 2 3 kgw Vertical 2kg Moment 2 4 Nm 5000km life expectancy Ma 4 5 0 46 Mb 5 4 0 55 Mc 4 1 0 42 1 At a speed of 10mm sec for 5 seconds 2 Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame 3 At an acceleration of 0 2G and speed of 400mm sec 4 Direction of load moment is Thrust direction lt gt 5 When the center of gravity for the attached object is the overhang length Ma Mc
7. 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Motor AC Servo Motor AC motor attached 192P R signal weve 2 2 Phase A Phase T LT Ll Pr S UNES NE Encoder Input voltage 5V rn Homing pulse 1 pulse 1 rotation 2 Ballscrew 10mm Lead 3mm Rolled thread C10 Backlash 0 1mm or less 3 Guide Direct recirculating ball bearing Hardened carbon steel ground track S Integrated motor axis and ballscrew axis 5 S Base Exclusive extruded aluminum A6N01S T5 equivalent White alumite treated Slider Special steel alloy Side Cover Exclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Mc direction FS Mb direction Ma direction 43 ii S N M b Mc direction Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease rease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SA5SL 50 100 150 200 250 300 350 400 450 500 Maximum Thrust 1 N kgf 131 4 13 7 Payload 2 3 kgw Horizontal 8kg Vertical 4kg 5000km life expectanc Moment 2 4 y 9 4 9 0 5 Mb 6 8 0 7 Mc 11 7 1 2 Mc 7 8 0 8 Overhang Load 2 Length L 5 mm Ma 150 or less Mb Mc 150 or less E 1 At a spee
8. 18 6 1 9 mm 220 orless Mb Mc 220 or less 8 1 At a speed of 10mm sec for 5 seconds 5 When the center of gravity for the attached 9 o 2 Even load distribution on the slider When designing work consider load object is the overhang length 2 moment Fix base securely to a flat strong frame 2 56 3 Atan acceleration of 0 3G and a speed of 800mm sec 4 Direction of load moment is Ma Mc moment 3 1 Specifications for the SlideType DS 1 2 Medium Speed DS SA6M DS SA6M 50 100 150 200 250 300 350 400 450 500 550 600 8 Stroke mm 50 100 150 200 250 300 350 400 450 500 550 600 a Rated Output W 30 8 Rated Speed mm sec 400 380 320 270 S Rated Thrust N kgf 48 4 4 9 Repeatability mm 0 02 Unit Weight kg 1 3 1 5 1 7 1 9 2 1 2 3 2 5 2 7 2 9 3 1 3 3 3 5 Motor AC Servo Motor AC motor attached 192P R Signal wave A B Z Phase APas L jl L g Encoder Input voltage 5V 1 LTL E EN Homing pulse 1 pulse 7 rotation Ballscrew 10mm Lead 6mm Rolled thread C10 Backlash 0 1mm or less D Guide Direct recirculating ball bearing Hardened carbon steel ground track 3 Integrated motor axis and ballscrew axis 3 S Base Exclusiv
9. home will move 1 5mm for every 90 change Page 49 3 Maintenance Arm Type 3 1 Maintenance Schedule Perform maintenance work according to the schedule below Start of operation After 1 month of operation After 6 months of operation After 1 year of operation Semiannually thereafter Annually thereafter 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 Note2 The end cover supports the ball screw so please do not remove it Do not remove the encoder cover as this contains precision equipment 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 3 3 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 of 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 lubrica tion Even if the grease you see around the parts is brown the lubrication is fine as long as the travelling surfaces app
10. 4 5B Start Input 30 4 6A OO1 User Input OO 4 002 User Input 4 YA Input User Input oO 004 User Input OG 4 8A 005 User Input OO 4 8B 006 User Input OG 4 9A 007 User Input DO 4 9B 008 User Input 30 4 10A 009 User Input oO 4 10B 010 User Input OO 4 11A O11 User Input OO 11B 012 User Input OG 4 12A O13 User Input OO 12B O14 User Input OG 4 13A 015 User Input 4 13B 300 Alarm Output Xx 4 14A 301 Ready Output 4 a Te 14B 302 User Output 4 15 303 User Output nl Pal 4 Output gt 15B 304 User Output t P 16A 305 User Output i gt 16B 306 User Output t t 4 17A 307 User Output 1 4 17B N24 External Current OV 24V Page 24 7 Connections S Controller The following is an example of connections with an external device in the position mode Pin No Signal Name 1 N 2 24V 3 24V 4 EMG SW I O Connector 34 pin Pin No Section Port No Function 1A P24 External Current 24V in out T 1B NC 2A NC 2B NC 3A NC 3B NC 4A NC 4B NC 5A CPU Reset 5B 000 Start Input DO 4 6A 001 Hold Input OQ 6B 002 NC YA Input NC 7 004 Position
11. 4 13 4 Payload 2 3 kgw Vertical 4kg 5000km life expectancy Moment 2 4 N m kgf m 4 5 0 46 Mb 5 4 0 55 Mc 4 1 0 42 At a speed of 10mm sec for 5 seconds Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame At an acceleration of 0 2G and a speed of 200mm sec Direction of load moment is we nur uoneorddy A N Thrust direction lt gt Page 68 5 When the center of gravity for the attached object is the overhang length Appendix DS 1 Trouble Shooting 1 VO connector is not connected Connect the I O connector 2 VO connector 24V is not supplied to pin 1A and Supply power against the I O VO connector OV is not supplied to pin 17 connector Pin 1A 24V of O connector and pin 17B OV Check the VO wiring were reversed RES reset appears 4 100V 200V was input to the VO connector Check the wiring on the LED display when power is supplied 5 Output ports load exceeds 100 Check the load ratio Total load of output ports exceeds 140mA Check the load ratio N side of the controller main power was not Check the main power connected properly wires From the above causes 3 4 5 6 and 7 the circuit Referent component protection CCP has been damaged 1 Emergency stop activated Release emergency stop The wiring is disconnected at the emergenc
12. 4 Heat Dissipation and Mounting A Alo JA Air Flow According to Natural Convention This controller is designed for assembling inside the control board Since the heat dissipation for this controller is about 10 12W cooling is done according to natural convention As for the spacing between the controllers whether or not it s a single or multiple controllers please leave enough space so that controller mounting and removal may be done easily 6 5 Power Supply to the Controller 1 Please make sure that the power is OFF when wiring into to the I O connector and main power 2 Please make sure that the N OV is common when setting the main power and I O power separately 3 To maintain safety during emergency stop when cutting off the main power of the controller close open just the 24V side Page 21 7 Connections D Controller 7 1 Connection Method Please make sure that all connectors are plugged in correctly and securely Excluding the TEACING RS232 PORT do NOT plug or unplug the connectors while the power is ON Teaching Pendant DS Option You may not use other types of cables RS232 Cable 5m is included in the PC Software CONTRO
13. A At a speed of 10mm sec for 5 seconds Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame At an acceleration of 0 2G and a speed of 400mm sec irecti M Ma Direction of load moment is Thrustdirection lt gt 5 When the center of gravity for the attached object is the overhang length Thrust direction _ gt ED Page 65 2 Specifications for the ArmType DS 2 2 L ow Speed High Thrust DS A6L Model DS A6L 50 100 150 200 in Stroke 50 100 150 200 m Rated Output W 30 Rated Speed mm sec 200 8 Rated Thrust N kgf 96 8 9 8 5 Repeatability mm 0 02 Unit Weight kg 3 0 3 3 3 6 3 9 Motor AC Servo Motor AC motor attached Signal A B Z phase Voltage output wave Input voltage 5V APhase L L LT L ZPhse Homing pulse 1 pulse 7 rotation Specifications Dry single head on when deenergized electromagnetic brake Model MCNB1 5 03 g Brake Holding torque N kgf 147 0 15 0 14 7 1 5 S5 Mounting position Ballscrew axis 3 Rated voltage DC24V D Ballscrew 10mm Lead6mm Rolled thread C10 Backlash 0 1mm or less Guide Integrated with base DS dedicated roseus Timing belt Reduction ratio 7 onnection Slider Hardened alloyed steel Base Extruded aluminum A6NO01S T5 White alumite
14. A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SA4H 50 100 150 200 250 300 Maximum Thrust 1 N kgf 39 2 4 0 Payload 2 3 kgw Horizontal 4kg Vertical 1kg Moment 2 4 d 5000km life expectancy 2 7 0 28 Mb 3 9 0 4 6 8 0 7 Overhang Load Length L 5 mm 120 or less Mb Mc 120 or less At a speed of 10mm sec for 5 seconds Mb direction Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame At an acceleration of 0 3G and a speed of 665mm sec Mc direction Direction of load moment is indicated on the right e 5 When the center of gravity for the attached E object is the overhang length EM N ywq Ma Mc moment Mb Mc VA i fa Standard location of offset TT Vedi oj 1 1 Specifications for the SlideType 1 8 Medium Speed DS SA4M Model DS SA4M 50 100 150 200 250 300 o Stroke mm 50 100 150 2
15. BGSR Error Step 1 is a BGSR Error B9 DO EDDO Pair Error DO and EDDO are not the same quantity BA DO Nest Over Error DO was used more than 15 times BB IF Pair Error IF and ELSE are not the same quantity BC ELSE Error ELSE was used in a place which was not between IF and EDIF C0 No Homing Error Homing was not performed before running actuators C1 Point Data Error Attempt has been made to executed unregistered point data C2 Axis Double Execution Error Move command given to axis currently moving C3 Software Limit Error Software limit exceeded in program CE S Motion Percent Error S motion percent ws set outside the range of 0 50 00 Acceleration Error Acceleration exceeds limits D1 Velocity Error Velocity has not been set D2 Override Error Override was set outside the range of 1 100 04 Axis Pattern Error D5 Axis Number Error Axis number was set outside the range of 1 8 D7 Program Number Error Program number exceeds the limit D8 Position Number Error Position number exceeds the limit D9 Point Number Error Negative number was input in the point number DA Flag Number Error Flag is not assigned correctly DB Variable Error Variable is not assigned correctly DC Digits Over Error Assigned number exceeds 8 digits binary 32 bits DD Division 0 Error Result of the division is 0 DF Task Level Error Task level was set outside of the range of 1 5 E0 Undefined Command Error Attempted to execute undefined command E1 Subroutine Over Nesting E
16. Controller 2 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 nstall a surge absorber parallel to the reactance load solenoid and relay 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 the reactance load solenoid and relay coils This will reduce noise in a wide band of frequencies rge Absorber Metal Oxide Varistor or Transzorb surge Killer Resistor Capacitor Snubber Page 19 6 Installation Environment and Noise Measures DS Controller Install a diode in parallel with a coil e Diode Capacity is determined by the load capacity Circuit Example DS Controller OUT In the case of DC power be careful not to exceed the diode polarity as this can lead toa breakdown of the diode inside the controller or of the DC power VO3C D 2 cR 100V 1 9 r MY2 DC24V OV ENB221D 14A OV Solenoid Valve Page 20 6 Installation Environment and Noise Measures DS 6
17. Mb Thrust ee gt 67 2 Specifications for the Arm DS 2 4 Low Speed High Thrust DS ASL Model DS A5L 50 100 150 200 Stroke mm 50 100 150 200 g Rated Output W 20 5 Rated Speed mm sec 200 S Rated Thrust N kgf 65 7 6 7 5 Repeatability mm 0 02 Unit Weight kg 22 24 2 6 2 8 Motor AC Servo Motor AC motor attached Signal 2 phase Voltage output wave Input voltage 5V APhase L Encoder BPhasee L T L ZPhse LU o 3 Homing pulse 1 pulse otation 2 Specifications Dry single head on when deenergized electromagnetic brake MB33 Holding torque N kgf 103 0 10 5 A 0 098 1 0 5 Mounting position Ballscrew axis 3 Rated voltage DC24V 3 Ballscrew 10mm Lead 6mm Rolled thread C10 Backlash 0 1mm or less 3 Guide Integrated with base DS dedicated gr aa Timing belt Reduction ratio 72 onnection Slider Hardened alloyed steel Base Extruded aluminum 1 5 White alumite treated Side Cover Extruded aluminum A6063S T5 White alumite treated Motor Housing Aluminum die cast Baked finish Encoder Cover Pulley Polyacetal plastic Cover Cable 11 conductor composite cable 5m standard length Cease Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Maximum Thrust 1 N kgf 131
18. Model DS SA6H 50 100 150 200 250 300 350 400 450 500 550 600 8 Stroke mm 50 100 150 200 250 300 350 400 450 500 550 600 Rated Output W 30 Rated Speed mm sec 800 760 640 540 Rated Thrust N kgf 24 2 2 4 Repeatability mm 0 05 Unit Weight 13 15 17 19 21 23 25 27 29 31 33 35 Motor AC Servo Motor AC motor attached 192P R Signal wave A B Z Phase A Phase ae _ d Encoder Input voltage 5 LT L C Phase ep 2 Homing pulse 1 pulse 1 4 rotation Ballscrew 10mm Lead 12mm Rolled thread C10 Backlash 0 1mm or less S Guide Direct recirculating ball bearing Hardened carbon steel ground track 9 er Integrated motor axis and ballscrew axis S Base Exclusive extruded aluminum A6NO1S T5 equivalent White alumite treated 3 Slider Special steel alloy Side Cover Exclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Cable 11 conductor composite cable 5m standard length MEN Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SAeH 50 100 150 200 250 350 400 450 500 550 Maximum Thrust 1 N kgf 72 7 3 Payload 2 3 kgw Horizontal 6kg Vertical 1 5kg Moment 2 4 m life eae 8 9 0 9 Mb 12 7 1 3
19. No 1 Input OG 8A 005 Position No 2 Input OG 8B 006 Position No 4 Input OG 9A OO7 Position No 8 Input OG 008 Position No 10 Input 10A 009 Position No 20 Input 10B O10 Position No 4O Input OO 11A O11 Position No 8O Input OQ 11B 012 Position No 100 Input OO 12A O13 Position No 200 Input OG 12B 014 Position No 400 Input OO 13A 015 NC 13B 300 Alarm Output 14A 301 Ready Output 14B 302 Position Completion Alarm 15A 303 NC Output 15B 304 NC 16A 305 NC 16B 306 NC 17A 307 NC 17B N24 External Current OV 24V Page 25 8 Moving the Actuator DS Controller 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 recorded positions 8 1 Program Mode There are two methods of operating the actuator in the program mode The first is operation from a teaching pendant and operation using the 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 Automati ration using th utomatic operation using the
20. Phase DEPT ME Homing pulse 1 pulse 1 4 rotation 2 Ballscrew 10mm Lead 6mm Rolled thread C10 Backlash 0 1mm or less 2 Guide Direct recirculating ball bearing Hardened carbon steel ground track gd Ballscrew Integrated motor axis and ballscrew axis 3 onnection E Base Exclusive extruded aluminum A6NO1S T5 equivalent White alumite treated 3 Slider Special steel alloy Side Cover Exclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease rease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SASH 50 100 150 200 250 300 350 400 450 500 Maximum Thrust 1 N kgf 33 3 3 4 Payload 2 3 kgw Horizontal 4kg Vertical 1kg 5000km life expectanc Moment 2 4 kot EF 9 4 9 0 5 Mb 6 8 0 7 Mc 11 7 1 2 7 8 0 8 Overhang Load B Length L 5 mm Ma 150 orless Mb Mc 150 or less 1 At a speed of 10mm sec for 5 seconds 5 When the center of gravity for the attached 2 Even load distribution on the slider When designing work consider load object is the overhang length S moment Fix base securely to a flat strong frame I 5 3 At an acceleration of 0 3G and a speed of 800mm sec ee rj 4 Direction of load moment is 3 Mb dire
21. Update Functions Software update via network or floppy disk Input Output DC24V Non insulated Page 10 4 Specifications DS Controller 4 2 External I O Specifications External Input Circuit External Power Voltage DC 24V 10 Input Current 7mA DC24V ON OFF Voltage ON voltage DC 18 OV OFF voltage Main DC 6 OV Insulation Non insulated No voltage contact point minimum load about DC 5V 1mA Extent Connection Photoelectric proximity sensor NPN type Device PLC Transistor output open collector type PLC Contact point output minimum load about DC5V 1mA Note When no contact circuit is connected to an external circuit make sure that the leakage current is under 1mA when the switch if OFF or it could cause faulty operation External Output Circuit Item Specification Load Voltage DC 24V maximum Load Voltage 100mA 1 point 400mA peak all current Application for er 7062084 20 1 point Voltage Leakage Current Max 0 1mA InsulationExternal Non insulated External Connection Miniature relay Device Sequence input unit sink type Note 1 For all of the external outputs the flyback diode D is connected on the inside Note 2 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 11 4 Specificatio
22. aia 18 6 3 Noise Suppression de toes 16 6 4 Heat Dissipation and Mounting sssri yes 21 65 Power Supply to the Controller PEE suse E 21 7 Connections 22 25 TA Connection Method nem tete E E EE RUE RS asia 22 72 Diagram of External Device Connector 25 8 Moving the Act ator s 26 34 8 1 Program Mode sine a eeaeee ter fte e 27 82 Operation Using the Positioning Mode sse ener nnne nennen entren nee ne terere inen en nennen 30 9 Error Code List serenrerenverenverenvenvnvenvnsenserenserenserensereneerenserenserensensnsenenseneeseneesensenenserenserenserenserensensnsenensensnsensnsensesensesensessnsere 35 10 Maintenance eeeerenverenveveneevenenvensenensenensenensnnenssnensenensenennenennenennensnenssnennsvennsvennsvennnennsvennevennevennennsnenasvevnsvennsvennsvennsvesnevennee 36 Part II DS Actuator Slider 3 7 40 1 General reeerenenrenenreneerenenreneenenennenenvensenensenenssnensenensenennenennenennevennevennennsnenssnennsvennsvennsvennsvennsvennsvennsvennevennevennenasnevnsnevnseevnee 37 1 1 Part Names cioe Rer inr re ee ope dep ente ee en Ei eme tpe ie pe Peer 37 12 Operating Environmebt ofr ert e Pe de md ie metr e m a e
23. 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 IAT Page 52 3 Maintenance Arm Type 3 Replacing the timing belt Follow the procedure below to replace the timing belt Motor pulley Motor bracket Timing belt 4 Adjusting the tension of the timing belt Large pulley Motor bracket Motor pulley To putthe belt on match Hexagonal bolt itto the marked position M4x20 1mm F 1009f Check tension Page 53 O Mark the pulley and motor bracket so that you do not change home position Loosen the four bolts Put the new belt on while pushing the motor up After the new belt is in place do the same pro cedure 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 3 Maintenance Arm Type 3 6 Inspecting and Adjusting the Brake 1 Brake inspection Set screw Inner driver 055 DS A5 Stator Armature Seal DS4 DS A4 54 Remove the screw cover to inspect the brake Visually check the condition of t
24. reset input outputs when the protective function of the controller operates Upon releasing the input of the emergency stop or by releasing the input of CPU reset the controller will restart Position Number Input Input is possible up to 500 positions using the BCD input Example No 100 No 20 No 4 No 1 Position No 125 Page 31 8 Moving the Actuator Controller 4 Timing for Position No Switching Position No Input External Start u B Position 2 execution start Input A Position 1 execution start Positioning Complete d EI Movin Output 9 moving The timing for 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 32 8 Moving the Actuator Controller 5 Timing of Motion Using a Hold Signal Position Input movement 7 f 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 Page 33 8 Moving the Actuator Controller 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 50000 on Select Position Number 6 300 150000 External S
25. 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 Cables 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 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 will not run properly in this condition Page 36 1 General DS Slider Type 1 1 Part Names Dust shield mounting bolt Front cover Slider cover Dust shield Slider 2 gt Side cover _ Side cover mounting bolt d Dust shield mounting bolt Motor housing Encoder cover Side cover Side cover mounting bolt Please note the following when handling the actuator To handle the actuator support it from underneath or grasp the area around the side cover mounting bolts Do not place excessive load on the cable Do not place he
26. 0 77kgf m 4 3N m 0 44kgf m 2 3 Wiring Cable The actuator cable is resistant to bending fatigue but itis not robot cable Avoid housing the cable in movable wire duct with a small radius In an application where the cable cannot be 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 4 Adjusting 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 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 2 5 Load on theActuator Do not exceed the load shown in the specification table as indicated in Chapter 4 of this manual Please note in particular the slider moment 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 1 2 of the rated value Mb mms EET E Page 40 3 Maintenance DS Slider Type 3 1 Maintenance Schedule Perform maintenance work according to the schedule below Maintenance Checkpoints Visual Check for loose Check inspection dust shield interior Aft
27. 00 250 300 E Rated Output W 20 Rated Speed mm sec 330 Rated Thrust N kgf 39 2 2 0 Repeatability mm 0 02 Unit Weight kg 06 07 0 8 0 9 10 1 1 Motor AC Servo Motor AC motor attached 192P R Signal wave e A B Z Phase APhase Lo T LL 5 Encode Input voltage 5V T LT L 3 C Phase JW Homing pulse 1 pulse 7 rotation 5 Ballscrew 8mm Lead 5mm Rolled thread C10 Backlash 0 1mm or less 9 Guide Direct recirculating ball bearing Hardened carbon steel ground track le od BAGEN Integrated motor axis and ballscrew axis 5 onnection 5 Exclusive extruded aluminum A6N01S T5 equivalent White alumite treated Slider Special steel alloy Side Cover Eclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic jur uoneorddy Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SA4M 50 100 150 200 250 300 Maximum Thrust 1 N kgf 78 4 8 0 Payload 2 3 kgw Horizontal 5kg Vertical 2 5kg Moment 2 4 i 5000 ab a Ma 2 7 0 28 Mb 3 9 0 4 Mc 6 8 0 7 LC mm Ma 120 or less Mb Mc 120 or less Ne object is the overhang length At a speed of 10mm se
28. 3 4 Lubrication When the grease contains dust becomes dull in color or begins to wear away through extended use lubricate the actuator using the procedure below 1 How tolubricate 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 slider apply grease to the underside of the slider with your finger then spread it out by moving the slider back and forth 2 What grease to use IAI uses lithium grease No 2 There are other brands of grease commerciallly 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 43 3 Maintenance Slider Type 3 Replacing the cover Inside the slider cover is a spring that allows it to fol low along the dust shield Lift the shield up from the bottom and attach the side cover 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 kgem After completing the inspection replace the cover Page 44 3 Maintenance Slider Type 3 5 Checking the Dust Shield The dust shield is made from stainless steel and is adjusted at the
29. 32 PORT Page 17 6 Installation Environment and Noise Measures D S Controller 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 2 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 3 Do not expose your controller to direct sunlight or place it near a heat source 4 The controller should be used in an environment where the ambient temperature is 0 4 0 C humidity 85 or less no condensation and is free of corrosive or inflammable gases 5 Avoid external vibration unnecessary impact or excessive shocks to your controller 6 Take steps to shield all cables and wires from electromagnetic noise 6 2 Power Source Power supply is DC24V 6 3 Noise Supression This section explains noise suppression measures when using the controller 1 Wiring amp Power For grounding please use a dedicated ground of Class D or better The thickness of the cable should be 2 0 5 5mm or larger DS Controller Other DS Controller Other TG Class 3 ground Correct Avoid this method Page 18 6 Installation Environment and Noise Measures D S
30. 500 550 600 Maximum Thrust 1 N kgf 290 29 5 Payload 2 3 kgw Horizontal 12kg Vertical 6kg 5000km life expectanc Moment 2 4 y 9 Ma 8 9 0 9 Mb 12 7 1 3 Mc 18 6 1 9 Overhang Load E Length L 5 mm 220 orless Mb Mc 220 or less 5 1 At a speed of 10mm sec for 5 seconds 5 When the center of gravity for the attached 2 Even load distribution on the slider When designing work consider load object is the overhang length 9 Oo moment Fix base securely to a flat strong frame 5 3 At an acceleration of 0 2G and a speed of 200mm sec ee 4 Direction of load moment is Ma Mc moment 3 Mb direction Standard location of offeset ee irecti Ma directi Mc rection a direc on 722 68 Mb Mc direction Page 58 1 Specifications for the SlideType DS 1 4 High Speed DS SA5H Model DS SASH 50 100 150 200 250 300 350 400 450 500 E Stroke mm 50 100 150 200 250 300 350 400 450 500 S Rated Output W 20 8 Rated Speed mm sec 800 760 S Rated Thrust N kgf 16 7 1 7 Repeatability mm 0 05 Unit Weight kg 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Motor AC Servo Motor AC motor attached 192P R Signal wave A B Z Phase APase LTL Input voltage 5V BPhase J LT L c C
31. Controller eoe sessec j 3 1 Safety Precautions and Warranty 4 e eeee ee eee sees eee ee eee eese en etas ense ta sense tasso setas eese eoe so aae 4 De SEUNS D PE 5 3 Part Names and Functions eserenvenvnvenvnvenverenverenverenverensereneenensnnvnennsnsenvervnvernnversnsnesnsensnesenneeesnennsnennsnennsesnaveennseesnsvesnenesnee 6 9 3 1 Part Names EID 6 7 33 Explanation of Code Display ueteri e D De rat 9 4 Specificati NS eS 10 16 4 1 Controller Specifications inii oct eo er ree p I cases ee e eo tox eie e EG etuer ev eo EIER Age sd 10 42 External I O Specifications eee itte te Deep t e E 11 AD nterface 13 44 TEACHING RS232PORE sunni hr i ror CR A Up d tnr P RR RR REIR 15 45 PORT ere eua it AER 16 5 Dimensions 17 safes sete e D i 17 6 Installation Environment and Noise Measures reeerenverenverensevensenensenensenensenensenensenennenennenennenennensenensenensenensenenssnensenene 18 21 6 1 Installation Environment s terr RR Ee RUE PNEU ERR EC E UNE Re ERR ee TEE UE TRE der EUR spans dye 18 6 2 Power t
32. EMERGENCY STOP input will release a Power 24V DC must be supplied to the external I O b Input pin No 5A for the external I O should be logically OFF If the CODE display is r EG then either a CPU reset has been input or I O current is disconnected The controller preparation is now complete Note 1 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 Note 2 Do not recycle power quickly Page 23 7 Connections Controller 7 2 Diagram of External Device Connector The following is an example of connections with an external device in the program mode Pin No Signal Name 1 N 2 24V 3 24V 4 EMG SW EMG SW I O Connector 34 pin ele Pin No Section Port No Function 1A P24 External current 24V in out 1B PRG No 1 Input 2A PRG No 2 Input z 2B PRG No 4 Input o 3A PRG No 8 Input M 3B PRG No 10 Input a 4A PRG No 20 Input 4B Reserve 5A CPU Set Input 606
33. G22 1 25mm AWG 16 Standard diameter 0 18 or greater Standard line length 11mm Suitable tool for button operation Slot screwdriver axis diameter 3 width of tip 2 6 Note This controller does not have a power switch Page 8 3 Part Names and Functions Controller 3 3 Explanation of Code Display _ Open display EI fa e Serial check display FEL LLLA Servo check display lela re Program check display SFC Ready display Pre Flash memory copy display Flash memory copy complete display Update display Emergency stop display ata uta about CPU reset HEr Homing display ae Startup program No display Position No display 001 500 mE LLL Interrupt error display REESE LL LLL Software error display ER Other error display Page 9 4 Specifications DS Controller 4 1 Controller Specifications eee Temperature 0 40 C Humidity 85 RH or less Free of corrosive gas no excessive dust 500V 10 or more Driver alarm Safety Features Motor excess current Excess voltage Driver temperature check Overload Check software limit check 32 programs Multi task function maximum of 8 programs Dedicated inputs 8 PRG No 1 2 4 8 1 20 Dedicated inputs 1 START User inputs 15 Dedicated outputs 2 Ready ALARM User outputs 6 Data Input Method Teaching Pendant or RS232 Communication Remote
34. LI ri CODE READY 2 m ALARM Om 00 000 000 D Emergency Stop SW Box PC Software Option LO OFF PORT IAI Corporation 5m POWER EMG OOOO gt 24V e a fufu E pn E sm EMG ll 24VPower SW L LIL Over 2A d 2m Page 22 7 Connections DS Controller 1 Connect the motor encoder cable and brake cables 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 24V power to the controller terminal block power a Power Terminal Block as shown on Page 6 b External I O device connector between Pin No 1A 24V cable color brown and Pin No 17B OV cable color yellow 4 If the CODE display shows amp Gru gt Hra gt ratt in sequence then the DS Controller is ready to operate If the CODE display shows Li khen the
35. Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Hui uoneorddy Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease rease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SA4L 50 100 150 200 250 300 Maximum Thrust 1 N kgf 156 8 16 0 Payload 2 3 kgw Horizontal 5kg Vertical 4 5kg 5000km life expectanc Moment 2 4 ktm 9 2 7 0 28 Mb 3 9 0 4 Mc 6 8 0 7 Overneng Load mm Ma 120 orless Mb Mc 120 or less Length L 5 1 At a speed of 10mm sec for 5 seconds Mb direction 2 Even load distribution on the slider When designing work consider load MSS moment Fix base securely to a flat strong frame aL 3 At an acceleration of 0 2G and a speed of 165mm sec ded i E 4 Direction of load moment is indicated on the right Modlecton Ma direction 5 When the center of gravity for the attached A gt Ma Mc moment object is the overhang length fev 53 Standard location of offset C H L Ly ie ls VA 7 Mb Mc WY ude e i Madirection e 3l e direction ZA i I 9 EA Em a a Li Page 64 2 Specifications for the ArmType DS 2 1 Mediu
36. No input The program number from the lt Program No command external device is input as a BCD code Program No confirmed SE External start input lt Start signal ON When the program is executed the c m number of that program shows up C Program operation Emergency stop in the code display on the controller front panel 4 Emergency stop input l Emergency stop signal confirmed Start signal confirmed Start signal from the external device is input lt signal ON When an emergency stop signal from the external device is input or NI Controller if the controller malfunctions the x er controller turns the servo OFF l READY lamp turns OFF C Servo OFF ALARM output gt ALARM signal N ALARM signal ON I b When the ALARM signal turns ON the ALARM lamp red on the l controller front panel lights up C ALARM processing L Page 27 8 Moving the Actuator Controller 2 Timing of Each Signal When exchanging signals with an external device timing becomes critical See the timing charts that follow Timing of Each Signal Ready The time from when the READY output Output turns ON until the external start signal can be input 1 50ms or more Program No Input The time from the program
37. any 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 carefully to make sure it is correct before turning the power ON since miswiring can lead to misoperation Warranty Period and Scope 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 The following are not cover
38. avy loads on the encoder cover slider cover or other plastic parts 1 2 Operating Environment Install the actuator in a place where the operator can work without protective gear See the table below for specific operating environment criteria Operating Conditions Ambient temperature 0 40 C Relative humidity 35 90 Avoid direct sunlight Avoid exposure to water cutting oil and other liquids Avoid exposure to corrosive or combustible gas Minimal dust Avoid strong electromagnetic waves ultraviolet rays and radiation Page 37 2 Installation D S Slider Type 2 1 Installing the Actuator SA4 SA5 Type 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 mounting holes located on the upper surface of the actuator The reamer holes on the back side for positioning pin may be used as needed Machine Type When opposite When opposite material is copper material is aluminum DS SA4 M3X35 DS SA5 M4X40 M4X45 For mounting bolts depending on the material of the foundation side use the bolt with hexagonal holes as indicated below _ Rest the actuator on mounting surface and check to see that 0 1mm thickness gauge cannot be inserted at th
39. c for 5 seconds Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame At an acceleration of 0 3G and a speed of 330mm sec Direction of load moment is indicated on the right When the center of gravity for the attached Mb direction Ma Mc moment Standard location of offset mA e 1312 Page 63 1 Specifications for the SlideType DS 1 9 Low Speed High Thrust DS SA4L Model DS SA4L 50 100 150 200 250 300 o Stroke mm 50 100 150 200 250 300 Rated Output 20 Rated Speed mm sec 165 Rated Thrust N kgf 78 4 8 0 S Repeatability mm 0 02 Unit Weight kg 06 09 10 1 1 Motor AC Servo Motor AC motor attached 192P R e Signal wave S APhase LTL Encoder Input voltage 5V BPhase I L M L o C Phase do l s Homing pulse 1 pulse 1 rotation e Ballscrew 8mm Lead 2 5mm Rolled thread C10 Backlash 0 1mm or less 3 Guide Direct recirculating ball bearing Hardened carbon steel ground track E jeden Integrated motor axis and ballscrew axis 2 Base Exclusive extruded aluminum A6NO1S T5 equivalent White alumite treated Slider Special steel alloy Side Cover Eclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel
40. connected the emergency stop is controlled by the external E stop connection Note When the controller is powered up plug in or remove the TEACHING RS232PORT connector when the PORT switch is OFF BAU R This is the switch for changing the Baud rate COPY This is the switch for COPY from ROM to FLASH memory F R 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 under normal circumstances This is a 25 pin RS232 connector for the teaching pendant or to a personal computer Page 7 3 Part Names and Functions D S Controller Brake connector Motor connector I O device connector Ground terminal block Power and emergency stop terminal block This is the actuator s brake connection This is the connector for connecting the actuator motor encoder cable This is a 34 pin I O connector This is the M3 screw for the ground connection This is the terminal for POWER N and 24V power The two EMG terminals are for connecting the emergency stop switch When the unit is shipped the EMG terminal is shorted POWER EMG EEE OOOO N 24V The user should meet the requirements and conditions given in the table below with respect to the power lines that are connected Suitable power line Solid wire 1 2 AWG 16 Standard wire 1 25mm AWG 16 Usable power line range Solid wire 00 4 AWG26 1 2 AWG 16 Standard wire 0 3mm AW
41. ction Ma Mc moment PET Standard location of offeset E direction 3 68 Mb Mc direction Ma direction age 1 Specifications for the SlideType DS 1 5 Medium Speed DS SA5M Model DS SASM 50 100 150 200 250 300 350 400 450 500 Stroke mm 50 100 150 200 250 300 350 400 450 500 e Rated Output W 20 8 Rated Speed mm sec 400 380 5 Rated Thrust N kgf 33 3 3 4 Repeatability mm 0 02 Unit Weight kg 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Motor AC Servo Motor AC motor attached 192P R Signal wave 2 Phase J LTL o Encoder Input voltage 5V BPase LT L C Phase UT t rA EE e Homing pulse 1 pulse rotation S Ballscrew 10mm Lead 6mm Rolled thread C10 Backlash 0 1mm or less 3 Guide Direct recirculating ball bearing Hardened carbon steel ground track 9 M Integrated motor axis and ballscrew axis g Base Exclusive extruded aluminum A6N01S T5 equivalent White alumite treated 8 Slider Special steel alloy mi Side Cover Exclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type g
42. d of 10mm sec for 5 seconds 5 When the center of gravity for the attached 26 3 2 Even load distribution on the slider When designing work consider load object is the overhang length ne moment Fix base securely to a flat strong frame ee 9 3 At an acceleration of 0 2G and a speed of 200mm sec r 4 Direction of load moment is 3 M a Mc moment Standard location of offset Ma direction Page 61 1 Specifications for the SlideType DS 1 7 High Speed DS SA4H Model DS SA4H 50 100 150 200 250 300 o Stroke mm 50 100 150 200 250 300 Rated Output W 20 Rated Speed mm sec 665 Rated Thrust N kgf 19 6 2 0 Repeatability mm 0 05 Unit Weight kg 0 6 0 7 08 09 1 0 1 1 Motor AC Servo Motor AC motor attached 192P R Signal wave A B Z Phase LTL Encoder Input voltage 5V BPhse l LT L C Phase d ULL Homing pulse 1 pulse 4 rotation jueuoduio jo eanjonas Ballscrew 8mm Lead 10mm Rolled thread C10 Backlash 0 1mm or less Guide Direct recirculating ball bearing Hardened carbon steel ground track ipie Integrated motor axis and ballscrew axis Base Exclusive extruded aluminum A6NO1S T5 equivalent White alumite treated Slider Special steel alloy Side Cover Exclusive extruded aluminum
43. e extruded aluminum A6NO1S T5 equivalent White alumite treated 3 Slider Special steel alloy g Side Cover Exclusive extruded aluminum A6063S T5 equivalent White alumite treated Dust Shield Stainless steel Motor Housing Aluminum die cast Baked finish Encoder Cover Front Cover Polyacetal plastic Slide Cover Cable 11 conductor composite cable 5m standard length Ballscrew Lithium type grease rease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Model DS SA6M 50 100 150 200 250 300 350 400 450 500 550 600 Maximum Thrust 1 N kgf 145 14 7 Payload 2 3 kgw Horizontal 12kg Vertical 3kg 5000km life expectanc Moment 2 4 d 9 Ma 8 9 0 9 Mb 12 7 1 3 Mc 18 6 1 9 Overhang Load Length L 5 mm 220 orless Mb Mc 220 or less 5 1 At a speed of 10mm sec for 5 seconds 5 When the center of gravity for the attached E 2 Even load distribution on the slider When designing work consider load object is 1 2 the overhang length 9 moment Fix base securely to a flat strong frame fu A 3 At an acceleration of 0 3G and a speed of 400mm sec 5 4 Direction of load moment is Mb direction Ma Mc moment T TUM Standard location of offeset 3 zx L oo Ma direction 4 EH 14 M b Mc direction Ma direction Page 57 1 Specifications for the SlideType DS 1 3 Low Speed High Thrust DS SA6L
44. e four mounting holes If the bolts go in a steel surface with tapped holes then use hexagon sockets with length shown in and if the surface is a light metal use the length in Page 38 2 Installation D S Slider Type S6 Type On the base of the actuator you can use the two mount ing holes at the motor end and the tapped holes on the underside of the base but please make note of the fol lowing Back Side Mounting Tap Holes em Suggested Tightening Torque When the bolt surface is When the bolt surface Bolt Size steel is aluminum 1 6N m 0 16kgf m 1 1N m 0 11kgf m 3 7N m 0 38kgf m 2 3N 0 23kgf m 7 5N m 0 77kgf m 4 3N m 0 44kgf m 22 Attaching the Workpiece Use the four tapped holes at the top of the slider to attach the workpiece Page 39 2 Installation D S Slider Type 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 Ma ke sure that the workpiece does not touch the slider cover and note the following Machine Type Slider Mounting Area Engagement Depth DS SA4 M3 depth 7mm Over 3mm Under 7mm DS SA5 M4 depth 9mm Over 4mm Under 9mm DS SA6 M5 depth 9mm Over 5mm Under 9mm When the bolt surface is When the bolt surface Bolt Size f steel is aluminum 3 7N 0 38kgf m 2 3N m 0 23kgf m 7 5N rh
45. ear shiny Page 50 3 Maintenance DS Arm Type 3 4 Lubrication When the grease contains dust becomes dull in color or begins to wear away through extended use lubricate the actuator using the procedure below 1 How to lubricate To lubricate the ball screw apply grease to the screw with your finger then spread it out by moving the slider back and forth Apply gn heri DP NETE To lubricate the slider remove the return cover at tached to the guide block and apply grease directly on the bearing Return cover 2 What grease to use IAI uses lithium grease No 2 There are other brands of grease commerciallly available for the ball screw 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 51 3 Maintenance Arm Type 3 5 Inspecting 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 Inspecting 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 replace 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
46. ed under the warranty even if the product is still under the warranty period a Damage due to incorrect handling or use that does not adhere to the instructions in the user s manual b When electrical or mechanical revisions have been performed on the product c Part wear when traveling distance has exceeded 5 000 km d Breakdown or damage caused by fire earthquake or other natural disasters e Any other breakdown or damage that is not recognized as the company s responsibility Page 4 2 Setting Up DS 1 Precautions When Using the Emergency Stop As a rule emergency stops should only be applied from the I O Do not turn the power AC117V ON OFF to effect an emergency stop If you stop the actuator by turning the power OFF wait at least 15 seconds before turning the power ON again If you disregard this warning and repeatedly turn the power ON OFF without waiting a sufficient amount of time you may damage the controller 2 Restarting the Controller After an Emergency Stop refer to part 3 1 4 Emergency Stop Release for details The Super SEL controller and Table Top type TT 300 both use a hard reset to restart after an emergency stop The opera tion is nearly the same as turning the power OFF ON Homing is required 1 Emergency Stop from the teaching pendant Press EMERGENCY STOP on the teaching pendant Continue pressing and the screen will display the following Teaching pendant display Controller code d
47. epair of the 1 incorrect contact of the Incorrect contact of the VO wiring has occured wiring has occured Check Check wiring VO circuit is chattering A Intermittent pulse on the O board has occured Stabilize the power supply 3 Noise and static electricity have occured on the Noise static electricity board compliance Page 70 Once output port is turned ON all ports have a output signal simultaneously Return for repair Check earth ground Static electricity or high level noise have Check noise static occured in the C P U electricity levels with compliance levels Return for repair Program position data and parameters are lost Intelligent Actuator Inc 2690 W 237th Street Torrance CA 90505 310 891 6015 310 891 0815 Fax www intelligentactuator com Publication Date January 1998 Publication IAI 065C 4th edition
48. er 1 month of operation Semiannually therafter Annually thereafter After 6 months of operation 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 Note2 The motor housing supports the ball screw so please do not disassemble The end cover supports the ball screw so please do not remove it Do not remove the encoder cover as this contains precision equipment 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 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 41 3 Maintenance S DS 3 3 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 of 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 surface appears shiny Page 42 3 Maintenance Slider Type
49. es 37 j EUn 9 38 40 211 Installing the IE Ral a ok Sees BORA Bis anions 38 2 2 Attaching the Work Piece eoe e e read dre Ec enes Mara Bees m testy eee eR es 39 23 Wari Cable 40 24 Adjusting the Home Position pere eoi 40 255 L0ad On the eue RIO eek aad neben 40 Table of Contents DS 3 Maintenance erenrnrenverenverenvereneereneerenserenserensenensenensenensenensenenrenensenensensenensenensenensenensenensenensenensenennensenensenenssvenssvenssvenseveee 41 45 3 1 Maintenance Schedule eite eene eie E GS e eie ine x ed e e RE RE erter teten 4 32 Cleaning the EXterior etse a e celu EO I i asd e deed petet 41 33 Inspecting the nterior orent ertet b He yr Che erp oe PEE 42 34 iere rere ere 43 355 Checkmg the Dust Shield sa ae 45 Part iII DS Actuator Arm Type acorde iet e sete Peste 40595 L General UE Te MR DUE pee EET RAD 46 1 Part eet ended eie a ed een oit Oei 46 1 2 Operating Environment pede Ree Rte ep 46 2 Installation E 47 49 21 Installing the Actu tor 4 22 Attaching the Work cie oet eae eee eee tette one d eoe eee ttem eb ADEL 48 23 Wiring Cable
50. he brake O Peel off the seal to inspect the brake 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 3 Maintenance DS Arm Type 2 Adjusting the brake gap Normally the inner driver requires no maintenance but if adjustments are necessary use the following procedure 0 5 Inner driver 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 TT Release the brake and loosen the two set screws Set the inner driver about 0 5mm from where it would hit up against the arma Ballscrew axis ture Armature Stator Brake Cross Section 3 Attaching the cover 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 Page 55 1 Specifications for the SlideType DS 1 1 High Speed TypeDS SA6H Mb direction Mc direction Ma direction C I 2 M b Mc direction I S N Page 56 Standard location of offeset Ma direction m
51. hite User Output 4 Black 4 Brown Note PRG Program Please use pin No 1B PRG No 1 input through pin No 4A PRG No 20 for inputting program numbers 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 1 ON In this case the controller changes to reset status Page 14 4 Specifications Controller 4 4 TEACHING RS232PORT D Sub 25 DTE Special x lt SW ME ru ve mes 3 at PORT SW Oo Note Controller will E stop if Teaching RS232 port SW is ON with nothing connected 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 Pin numbers 4 and 5 are shorted Since pin numbers 18 and 19 are connecting terminals for the ENABLE SW it is necessary to connect these when the servo is ON TEACHING RS232 PORT SW PORT SW ON The teaching pendant or RS232 communication lines can be used PORT SW 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 Page 15 4 Specifications DS Controller 4 5 PORT MPG Connector me BK Connector Page 16 5 Dimensions Controller 5 1 Plastic Type Controller DS S C1 109 BRAKE RELEASE NORMAL TEAING RS2
52. isplay EMG STOP EG A red ALARM lamp lights up ReStart Flashing display F1 F2 Take your finger off the EMERGENCY STOP button to do a hard reset and the following screen appears Teaching pendant display Controller code display EMG STOP rd A green READY lamp lights up ReStart Flashing display Fi If you press the F1 key ReStart on the teaching pendant the initial screen reappears Teaching pendant display Controller code display rd A green READY lamp lights up F1 F2 Fa 2 Pressing the controller emergency stop button or an emergency stop condition caused by an external signal When the emergency stop is released after pressing the emergency stop button on the controller front panel you must follow the same procedure as described above or the teaching pendant will not reset you cannot operate the teaching box if the code display on the controller front panel reads EG Warning If you are using the Auto Start PRG in the system program parameter mode always write the program so that move ment will not resume unless there is some kind of input condition This is to avoid sudden startup of movement because of the automatic start program right after the emergency stop is released Page 5 3 Part Names and Functions DS Controller
53. ition 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 LL When the move is completed positioning complete signal is output When an emergency stop signal from the external device is input or if the controller malfunctions the controller turns the servo NI OFF READY lamp turns OFF When the ALARM signal turns ON the ALARM lamp red on the controller front panel lights up 8 Moving the Actuator DS Controller 3 Timing of Signals When exchanging signals with an external device timing becomes critical See the timing charts that follow POWER Homing Stop Move Stop Move Ready Output Positioning Complete Output External Start Input 1 T5 Position No Input i 1 i 1 1 The time from the READY signal ON to homing start input T2 External start input over 30msec T3 Thetime from the the previous positioning complete output ON to when the external start signal input can be entered 50msec T4 The time it takes from external start input ON to positioning complete output OFF T5 Thetime it takes to input from position number input to external start The interchange timing of each position number input is effective after receiving external start input Alarm Output During emergency stop input and during CPU
54. m Speed DS A6M uoneorddy Model DS A6M 50 100 150 200 Stroke mm 50 100 150 200 W Rated Output W 30 S Rated Speed mm sec 400 Rated Thrust N kgf 48 4 4 9 S Repeatability mm 0 02 Unit Weight kg 3 0 33 3 6 3 9 Motor AC Servo Motor AC motor attached Signal A B Z phase Voltage output Wave Input voltage 5V Phase FT as Encoder B Phase TL ZPhase 5 Homing pulse 1 pulse 72 rotation 3 Specifications Dry single head on when deenergized electromagnetic brake 9 Model MCNB1 5 03 s Brake Holding torque N kgf 73 5 7 5 AO 14 7 1 5 Mounting position Ballscrew axis Rated voltage DC24V 3 Ballscrew 10mm Lead 12mm Rolled thread C10 Backlash 0 1mm or less Guide Integrated with base DS dedicated MotonBalscrew Timing belt Reduction ratio 7 Connection Slider Hardened alloyed steel Base Extruded aluminum AGNO1S T5 White alumite treated Side Cover Extruded aluminum A6063S T5 White alumite treated Motor Housing Aluminum die cast Baked finish Polyacetal plastic Cable 11 conductor composite cable 5m standard length pee Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Maximum Thrust 1 N kgf 145 14 7 Payload 2 3 kgw Vertical 3kg Moment 2 4 N m 5000km life expectancy Ma 8 1 0 8 Mb 10 0 1 0 Mc 6 5 0 6 Ne
55. m 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 29 8 Moving the Actuator Controller 2 Positioning Controller External Device C Power ON Power ON J 2 READY output s READY signal ON D LY Position No confirmed LY READY signal confirmed processing 2 Position No input lt Position No command External operation input C Start signal ON J position Move to d Move complete b Positioning N omplete confirmed Positioning complete signal ON C processing 2 Position Controller Y abnormal N N_ Emergency stop signal confirmed complete output J Emergency stop Switen stop E ON a a ERE eC Servo OFF D LY ALARM signal ON ALARM vm confirmed C ALARM processing ALARM output i Page 30 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 pos
56. n off the controller power before pro ceeding 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 0 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 After mounting the actuator reattach the screw cover DS A6 M5x40 M5x15 DS M4X8 M4X12 DS A4 M3X8 M3X12 Page 47 2 Installation Arm Type 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 Part 4 Please note in particular the slider moment allowable overhang length and the load weight Keep the overhang at the upper portion of the workpiece to the measurements below to prevent interference between the screw cover and workpiece DS A6 T
57. n position mode use pin number 7B Port No 004 through pin number 12B Port No 014 for position number input Homing is performed when position number input is 0 OFF and start input is set to 1 ON 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 1 ON In this case the controller changes to reset status Positioning Complete Output 3 White 001 002 003 004 005 007 009 00 301 02 03 04 05 06 07 Page 13 4 Specifications Controller Program Mode I O Connector 34 pin Cenne seenen Ponne gt gt gt External currenrt 24v in out 1 Brown PRG No 1 Input PRG No 2 Input 1 Orange PRG No 4 Input 1 Green PRG No 8 Input PRG No 10 Input PRG No 20 Input Reserve CPU Reset Input Start Input User Input User Input User Input User Input User Input User Input Caution External 24V power must be connected to I O connector 1A pin and 17B Make sure that the power is OFF during connection and avoid short circuit and reverse connection User Input User Input User Input User Input 2 Purple 2 White User Input User Input 2 Black 3 Brown User Input User Input 3 Red 3 Orange User Input Alarm Output 3 Yellow 3 Green Ready Output User Output 3 Blue 3 Purple User Output User Output 3 Gray 3 W
58. ne 63 19 Low speed high thrust type DS SAAL 64 2 Specifications for theArm Type 65 68 2 1 Medium speed type Ib E 65 22 Low speed high thrust type 66 23 Medium speed type DSASM rense tg 67 24 Low speed high thrust type 58 51 68 si 09 70 1 Trouble Shooting era de dere e ete 69 Page 2 Foreword D S 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 programming Please read through this manual carefully to gain an understanding of the proper method of operating and handling the DS controller and actuator Page 3 1 Safety Precauitions and Warranty DS Safety Precautions This product was 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 Asa rule any handling or operating methods not described in this manual should be viewed as things that should not be attempted Please contact the comp
59. ne into breakdown Leakage current of output a 2av was not input to pin 1A of I O connector Check wiring port is significant The input LED display is lightly Damage has occured to the circuit component fokre Bale blinking protection CCP p Stops suddenly during movement without releasing an alarm Upon cycling power LED display dissapears and resets Communication with re is not Breakdown has occured in CMOS and RAM possible timeout error as well as in the surrounding circuitry and display shows error 4 Static electricity and high level noise in the Check earth Noise static main CPU CMOS and RAM have occured electricity compliance Breakdown has occured in the main CPU and surrounding circuitry as well as CMOS and Return for repair Breakdown has occured in the backup battery 3 Return for repair and surrounding circuitry 4 Poorly connected teaching pendant and PC Check connection or breakdown have occured Timeout error occurs without communicating 2 Possible bad wire in the teaching pendant Return for repair with the controller and PC cable pair Breakdown has occured in the controller s main Return for r vait CPU and surrounding circuitry P 1 Main power is not connected to the controller Check wiring Controller is not 100V 200V was input to the controller s main Return for repair receiving power Breakdown has occured on the power board Return for r
60. ns Controller External I O Circuit Circuit protective element R L CCP2E50 Fuse M p 24v W3 3KQ 220uH F No 100KQ V ZS IN 24 C R OUT 1 100 Lote Internal L 0 4 circuit Circuit protective element 250 OUT 600 N HE Page 12 4 Specifications DS Controller 4 3 Interface List Specifications for I O Interface during program mode and position mode are different The interface list for each is indicated in the following tables Position Mode I O Connector 34 Pin Section Porno Function m term Reserve Caution e External 24V power must be EU Reset Input connected to I O connector Start Input 1A pin and 17B Make sure Hold Input 28rown that the power is OFF during ici and evene circuit and reverse connection NC Orange Input Position No 8 Input 2 Purple NINH 9 Position No 20 Input 010 Position No 40 Input 011 Position No 80 Input Ouput NC No contact Do not use number 1B PRG No 1 input through pin number 4A PRG No 20 since these are for program number input Position mode can be used when program number input is 0 OFF When using the controller i
61. number is input until the external start signal can be input Outer Start Input 2 s30ms or more The time from the input of the external start signal T32 s30ms or more Page 28 8 Moving the Actuator DS Controller 8 2 Operation Using the Positioning Mode Operation Based on the External Start Signal Selection 1 Homing Controller 4 Power ON J READY output Ge C READY signal ON S confirmed C Homing Start Homing Complete Positioning E o Signal Position Complete Signal ON NOTE External start input N Start signal C Start signal ON External Device 4 C Power ON b READY signal confirmed Y Set all Position No command to OFF 0 ALARM signal N The positioning mode consists of Operation from the teaching pendant Operation using the PC software and Operation based on the external start signal selection This section explains the last method Once the READY signal is ON the READY lamp green on the controller front panel lights up Homing is performed when all position number inputs from the external device are OFF 0 and the start signal is input After homing is completed the positioning complete signal is output and the controller goes into a wait stage By homing for later operations commands fro
62. rease Grease Model Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent DS SASM 50 350 400 450 500 Maximum Thrust 1 N kgf 65 7 6 7 Payload 2 3 kgw Horizontal 8kg Vertical 2kg Momem dad Nm 5000km life expectancy kgfm 4 9 0 5 Mb 6 8 0 7 Mc 11 7 1 2 Mc 7 8 0 8 Overhang Load E Ak engtad dO omm dec for 5 seconds mm Ma 150 orless Mb Mc 150 or less 5 When the center of gravity for the attached N yw Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame At an acceleration of 0 3G and a speed of 400mm sec Direction of load moment is Mc direction object is the overhang length Ma Mc moment Standard location of offeset Mb direction Ma direction 3 C I N Mb Mc direction Ma direction Page 60 1 Specifications for the SlideType DS 1 6 Low Speed High Thrust DS SASL Model DS SA5L 50 100 150 200 250 300 350 400 450 500 Stroke mm 50 100 150 200 250 300 350 400 450 500 9 Rated Output 20 9 Rated Speed mm sec 200 190 5 Rated Thrust N kgf 65 7 6 7 Repeatability mm 0 02 Unit Weight kg 1 2
63. rror Nesting of more than 15 subroutines E2 Subroutine Under Nesting Error EXSR and EDSR are not making a pair E3 Controlling Column Error Use of condition is not correct EG EMG Error Emergency Emergency Stop was asserted FO Interrupt Error Motor CPU and Interrupt management do not match Note appears at the head of the error code followed by 3 digits Page 35 10 Maintenance D S Controller 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 n 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 specification range DC24V 1046 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 Check for loose controller mounting screws Tighten if necessary 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 can not be done if
64. tart Input 150 000 EE XXXXXX Movement Complete Positioning Complete ON E Im 34 9 Error Code list DS Controller When an error occurs the alarm LED red color on the controller s front side will light up At the same time the I O alarm output will turn ON and the READY output will turn OFF Error Code List Error Code Error Name Explanation 1 Motor over current A1 External Interrupt Error 2 Over regenerative current over negative load 3 Driver overheat A2 Motor Overload Error Mechanical overload of motor A3 Deviation Error Motor is unable to perform properly due to mechanical overload A4 Software Limit Error Exceeded software limit A5 Pole Sense Error Unable to sense pole BO No Program Error Program does not exist B1 Program Execution Error Execution of a currently executing program B2 Program Over Error Number of tasks exceeds those set as parameters B3 Double Subroutine Number Error Two or more of the same subroutine number are used B4 Double Tag Number Error Two or more of the same tag number are used B5 Undefined Subroutine Number Subroutine number is not defined B6 Undefined Tag Number Tag number is not defined B7 Subroutine Pair Error BGSR and EDSR are not the same quantity B8 Step 1
65. 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 ten sion in the shield Page 45 1 General Arm Type 1 1 Part Names Motor bracket Pulley cover Screw cover mounting screws Screw cover N Motor housing Encoder cover Please note the following when handling the actuator Support the base when handling the actuator Do not place excessive load on the cable Do not place heavy loads on the pulley cover encoder cover or other plastic parts 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 Ne Operating Conditions Ambient temperature 0 40 C Relative humidity 35 90 s 8 Avoid strong electromagnetic waves ultraviolet rays and radiation Page 46 2 Installation D S Arm Type 2 1 Installing the Actuator Mount the actuator to a machined surface or one of comparable precision This actuator has a built in brake Connect the con troller to the unit then release the brake with the brake switch After releasing the brake pull the slider to the stroke end Tur
66. treated Side Cover Extruded aluminum A6063S T5 White alumite treated Motor Housing Aluminum die cast Baked finish Encoder Cover Polyacetal plastic uoneorddy Pulley Cover Cable 11 conductor composite cable 5m standard length Gace Ballscrew Lithium type grease Guide Shell Albania Grease No 2 Mobil Mobilux No 2 or equivalent Maximum Thrust 1 N kgf 290 29 5 Payload 2 3 kgw Vertical 6kg Moment 2 4 Nm 5000km life expectancy Ma 8 1 0 8 Mb 10 0 1 0 Mc 6 5 0 6 Ne At a speed of 10mm sec for 5 seconds Even load distribution on the slider When designing work consider load moment Fix base securely to a flat strong frame Direction of load moment is At an acceleration of 0 2G and a speed of 200mm sec Ma Nn Thrustdirection lt gt 5 When the center of gravity for the attached object is the overhang length Page 66 Mb Thrust T ION 2 Specifications for the ArmType DS 2 3 Medium Speed DS A5M Model DS A5M 50 100 150 200 Stroke mm 50 100 150 200 Rated Output W 20 E Rated Speed mm sec 400 8 Rated Thrust N kgf 33 3 3 4 Repeatability mm 0 02 Unit Weight kg 2 2 24 2 6 2 8 Motor AC Servo Motor AC motor attached Signal A B Z phase Voltage output wave Input voltage 5V APhase LL
67. y stop Connect emergency stop terminal board of the controller wiring Emergency stop box of the PC cable is not Connect emergency stop connected to the PC cable box IN OUT of the PC cable are connected in reverse Check connection PC cable was not connected properly Connect properly Main power 24V and OV were connected in Swap connection reverse Non assigned cable was connected to the Comset assioned cable RS232C connector 9 100 200V was input to the controller Check wiring Protective source L1 of the ermergency stop circuit has shorted from above causes 7 8 and 9 E port was short circuitted to 24V due to no Check for wiring Load of output port exceeds 100mA for each pin Check load ratio Total load of output port exceeds 400 Check load ratio Output port was connected to 100 200 Check wiring Protective resistance of the output has broken etum for rebar down due to above causes 2 3 and 4 Transistor array TD62084 has broken down due Return for repair to above causes 2 3 and 4 ERG emergeny stop appears on the LED display once power is supplied 5 1 2 The output port does not 3 output is not in correct state A Page 69 Appendix DS Output port is wired incorrectly Check wiring Due to output port short circuit excessive load from excessive voltage the fly wheel diode of the transistor array TD62084 has go
68. ype A 70mm DS A5 Type A 65mm DS A4 Type A 53mm Slider SN IS Page 48 2 Installation D S 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 4 Adjusting 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 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 2 5 Changing Motor Position You can change the position of the motor for greater flexibility when installing the actuator Remove the pulley cover 2 Remove the four bolts M4 x 25 used to mount the motor bracket 3 While pushing the motor bracket lightly against the actuator rotate it and set the position 4 Reattach the motor bracket with M4 x 25 bolts 5 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 6mm

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