PULSE DRIVE
Operation Manual First Edition
Directions for Safe Use
Please read these “Directions for Safe Use” thoroughly before selecting a model and using the product.
The following precautions are provided so that you can use this product safely and avoid bodily injury
and/or property damage.
Please observe these precautions together with the safety regulations of JIS B 8433 (general rules for
industrial robots).
Directions are classified into “danger,” “warning,” “caution” and “note,” according to the
degree of risk.
Danger
Indicates an item where imminent danger causing death or serious injury
may occur if the product is mishandled
Warning
Caution
Note
Indicates an item where there is a risk of causing death or serious injury if
the product is mishandled
Indicates an item where there is a possibility of injury or damage to the
equipment if the product is mishandled
Indicates an item to be observed in order to use the product properly, even
though there is no possibility of damage
This product has been designed and manufactured as a component for general industrial
machinery.
Devices must be selected and handled by a system designer, person in charge of the system or similar
individual with sufficient knowledge and experience, after reading both the catalog and operation manual
(particularly the “Directions for Safe Use” section). Mishandling poses a risk.
Please read the operation manuals for all devices, including the main unit and controller.
It is the customer’s responsibility to verify and judge the compatibility between this product and the
customer’s system, and to use them properly.
After reading the catalog, operation manual and other materials, store them in a place where other users
will have easy access to them when necessary.
Be sure to attach the catalog, operation manual and other materials to the product conspicuously if you
transfer or lend the product to others, so that the new owner or user can understand its safe and proper
use.
The danger, warning and caution directions in this “Directions for Safe Use” do not cover every possible
situation. Please read the catalog and operation manual for the given device, particularly for descriptions
unique to it, to ensure its safe and proper handling.
Danger
z Do not use this product for the following applications:
This product is not designed for applications requiring a high degree of security. We do not guarantee the
safety of human life, and the guarantee coverage is limited to this delivered product exclusively.
General
1. Medical devices related to the support and maintenance of human life and body
2. Mechanisms and machinery used for the purpose of moving and transporting people
3. Important security components of machinery
Installation
z Do not use this product in a place where hazardous substances such as combustible, flammable or
explosive substances exist. There is a possibility of the product generating sparks, catching fire or
causing an explosion.
z Do not use this product in a place where there is a possibility of water and oil drops being splashed on
the main unit and controller.
z Never cut and reconnect the cable of this product in order to change the cable length. Doing so may
cause the risk of equipment catching fire.
Operation
z People using pacemakers or similar devices must not approach within one meter of this product.
Pacemakers may malfunction due to the magnetic field caused by the strong magnet within this product.
z Do not pour water on this product. Pouring water on the product, washing it or using it immersed in water
may cause injury due to abnormal operation, electric shock, fire, etc.
Maintenance, Inspection and Service
z Never modify this product. Doing so may cause injury due to abnormal operation, electric shock, fire, etc.
z Do not attempt to disassemble this product. Doing so may cause injury, electric shock, fire, etc.
Warning
z Do not use this product outside the specified range. Using it outside the specified range may cause
z Design a safety circuit or devices so that device damage and physical injury will not occur if the machine
z Make sure to perform D-class grounding (formerly third-class grounding, with ground resistance of 100
z Be sure to confirm the safety of the operating range of devices before supplying power to and operating
z Wire this product correctly while checking against the operation manual. Connect the cables and
z Do not touch the terminal blocks or switches while the power is turned on. There is a risk of abnormal
z Check to see that the servo is off (using the teaching pendant) before manually moving movable parts of
z The cables used are highly flexible but not robotic. Do not store them in a movable wiring duct (e.g.
z Do not damage any of the cables. Damaging, forcibly bending, pulling, winding or pinching cables, or
General
failure, breakdown and damage to the product. Doing so may also lead to a significant reduction in the
product’s useful life. Be sure to observe, in particular, the maximum load weight and speed
specifications.
Installation
stops at system errors such as emergency stop and electric power failure.
Ω or less) for the actuator and controller. There is a possibility of electric shock and malfunction in the
event of current leakage to the ground.
this product. If the power is supplied improperly, there is a risk of electric shock and injury caused by
contact with a movable part.
connectors securely so that they do not get pulled out or loosened. Failure to do so may lead to
abnormal operation of this product or fire.
Operation
operation and electric shock.
this product (such as manual positioning). Failure to do so may lead to injury.
cable bearer) whose radius is less than the specification.
placing heavy objects on them may cause current leakage, fire and/or electric shock due to poor
conduction, abnormal operation, etc.
z Turn off the power in case of electric power failure. Failure to do so may cause injury and product
damage, since the product may start moving suddenly upon recovery from the electric power failure.
z Turn off the power immediately if the product generates abnormal heat, smoke or odor. Failure to do so
may lead to product damage or fire.
z Turn off the power immediately if the protective device (alarm) of the product is activated. Failure to do
so may lead to injury due to abnormal operation of the product or may lead to the product being broken
or damaged. After turning off the power, investigate and remove the cause of the alarm before turning on
the power again.
z Turn off the power immediately if the LEDs of the product fail to light when the power is turned on. A
protective device (e.g. fuse) on the live side may be alive, not blown. Send a repair request to the sales
office from which you purchased the product. (All the LEDs should be turned off when an emergency
stop is activated.)
Maintenance, Inspection and Service
z Be sure to completely remove the supply of electricity before performing various tasks such as
maintenance/inspection, service or replacement. At this point, observe the following precautions:
1. Post a display, for instance “Work in Progress: Do not turn on the power,” in an easy-to-see location,
so that a person other than the operator does not turn on the power inadvertently while the operator
is working in the area.
2. If several operators are involved in the maintenance/inspection, do not turn the power supply on/off or
move the axis until the safety of all operators has been confirmed and all operators are made fully
aware of such operations.
z Do not throw this product into the fire. The product may explode or poisonous gases may be discharged.
Disposal
Caution
Installation
z Do not use this product in places subjected to direct sunlight (ultraviolet light) or dust, salt and iron
powder, humid places, or in an atmosphere containing organic solvent, phosphate-ester hydraulic oil, etc.
The product may stop functioning in a short period of time, or the performance may be deteriorated and
the lifetime of the product may be significantly reduced.
z Do not use this product in an atmosphere containing corrosive gases (sulfuric acid, hydrochloric acid,
etc.). The durability of the product may be diminished due to the generation of rust.
z Take appropriate shielding measures if this product is used in the following places. Failure to take such
measures may lead to a malfunction.
1. Places where large current or strong magnetic fields are generated
2. Places where arc discharges may occur, such as in welding operations
3. Places where electrical noise may be generated due to static electricity
4. Places that may be exposed to radiation
z Install the main unit and controller in a place with minimum dust and dirt. If they are installed in a place
filled with dust and dirt, they may malfunction.
z Do not install the product in a place where it may be subjected to strong vibration or impact (4.9 m/s
more). Doing so may result in the malfunctioning of the product.
z Place an emergency-stop breaker in an easily accessible location so that it is possible to stop the
operation of the product immediately in the event of a potential danger.
z When installing this product, be sure to secure sufficient space for maintenance. If sufficient space is not
secured, daily inspection and maintenance cannot be conducted properly, which will eventually lead to
device failure and/or damage to the product.
z Do not hold on to movable parts or cables of this product at the time of installation. Doing so may lead to
injury.
2
or
z Be sure to use genuine parts supplied by IAI for the cable between the actuator and controller. Moreover,
be sure to use genuine parts supplied by IAI for each component, such as an actuator, controller or
teaching pendant.
z Post a display, for instance “Work in Progress: Do not turn on the power,” when performing tasks relating
to installation, adjustment, etc., so that the power is not turned on inadvertently. If the power is turned on
inadvertently, there is a risk of electric shock or injury due to sudden activation of the actuator.
Operation
z Turn on the power to the host device first. Failure to do so may lead to injury or product damage, since
the product may be activated suddenly.
z Do not place fingers or objects in any of the opening parts of this product. Doing so may lead to fire,
electric shock and injury.
z Do not place floppy disks or other magnetic media within one meter of this product. Data stored on the
floppy disks may be damaged by the strong magnetic field caused by the magnet within this product.
Maintenance, Inspection and Service
z Do not touch the terminals when conducting the insulation-resistance test. Doing so may cause electric
shock. (Do not conduct the withstand voltage test on a product that uses a DC power supply.)
Note
z Be duly cautious in use by providing a sufficient margin to the stated rating and performance limitations,
z Do not place obstacles that prevent ventilation near the controller. Doing so may damage the controller.
z Do not configure control loops that may cause workpieces to be dropped in case of a power failure.
z When handing this product, wear protective gloves, safety glasses, protective footwear, etc., as
z If this product becomes unusable or no longer necessary, dispose of it properly as industrial waste.
General
as well as safety measures (for instance, failsafe measures), if you are considering using the product
under conditions or in environments not described in the catalog and operation manual. This also
applies if you are considering using the product for applications requiring special security such as air
navigation facilities, combustion equipment, entertainment devices, cleanrooms, security devices or
other situations where significant influence on the safety of human life and properties can be expected.
Be sure to consult our sales representative.
Installation
Configure the control loops so that tables and workpieces can be prevented from dropping in case of
power failure and/or the emergency stop of machinery.
Installation, Operation and Maintenance
necessary to secure safety.
Disposal
Others
Q IAI shall have no liability if the general precautions in “Directions for Safe Use” are not
observed.
Q For inquires about this product, please contact your local sales office. Addresses and
telephone numbers of sales offices are listed at the end of the operation manual.
Before Using the Product
Q Precautions
(1) Be sure to read this operation manual to ensure the proper use of the product.
(2) It is prohibited to use or copy any part of this manual without permission.
(3) Please be aware that we shall have no liability for any effects caused by operations not described
in this manual.
(4) The information provided in this manual is subject to change without notice.
Q Handling at Emergency
* If this product is in a dangerous condition, turn off all the power-supply switches of the main unit and
connected devices, or pull out all power-supply cords from their sockets. (A “dangerous condition”
refers to any situation where fire and physical danger can be expected due to abnormal heat, smoke
and/or fire.)
Table of Contents
1. Overview............................................................................................... 1
1.1 Features .......................................................................................................................................... 1
1.2 Name and Function of Each Part of the Controller ......................................................................... 2
1.3 How to Read the Model Specification.............................................................................................4
1.4 Applicable Actuators ....................................................................................................................... 4
1.5 Options............................................................................................................................................ 5
(1) PC Software (Model PDR-101-MW)........................................................................................ 5
(2) External I/O Cable (Model CB-PD-PIOS020) .......................................................................... 5
(3) Regenerative Resistance Unit (Model REU-1) ........................................................................ 6
2. Specification ......................................................................................... 7
2.1 Specification List ............................................................................................................................. 7
2.2 External Dimensions ....................................................................................................................... 8
3. Installation and Noise Prevention ......................................................... 9
3.1 Installation Environment.................................................................................................................. 9
3.2 Supply Power .................................................................................................................................. 9
3.3 Noise Prevention and Grounding.................................................................................................... 9
(1) Wire and Power Supply ...........................................................................................................9
(2) Grounding for Noise Prevention ............................................................................................ 10
(3) Protecting Against Noise Emitting Sources ............................................................................11
3.4 Heat Dissipation and Installation................................................................................................... 12
4. Wiring ................................................................................................. 13
4.1 Configuration................................................................................................................................. 13
4.2 Connection Diagram ..................................................................................................................... 14
(1) Standard................................................................................................................................. 14
(2) Option .................................................................................................................................... 15
4.3 Power-Supply Input Interface........................................................................................................ 16
(1) Commercial Power ................................................................................................................16
(2) Emergency Stop .................................................................................................................... 17
(3) Electromagnetic Brake Power-Supply Input.......................................................................... 18
4.4 I/O Signals..................................................................................................................................... 18
4.5 I/O Signal Interface Circuit ............................................................................................................ 21
(1) Sequence Input Part.............................................................................................................. 21
(2) Sequence Output Part ........................................................................................................... 22
(3) Command Pulse-Train Input Part .......................................................................................... 23
(4) Feedback Pulse Output Part.................................................................................................. 24
4.6 Motor Cable Connector................................................................................................................. 25
4.7 Encoder Cable Connector............................................................................................................. 25
4.8 Sensor (Optional) Input Connector ...............................................................................................26
4.9 Regenerative Resistance Unit Connector..................................................................................... 26
4.10 RS232C Interface ......................................................................................................................... 27
5. Control and Function of I/O Signals.................................................... 28
5.1 Input Signals ................................................................................................................................. 28
5.1.1 Servo ON Signal (SON)......................................................................................................... 28
5.1.2 Alarm Reset Signal (RES) ..................................................................................................... 29
5.1.3 Homing Command Signal (ORGC)........................................................................................ 30
5.1.4 Torque Limit Selection Signal (TL)......................................................................................... 30
5.1.5 Forced Stop Signal (CSTP) ................................................................................................... 31
5.1.6 Command Pulse Inputs (PP, /PP, NP, /NP)............................................................................ 31
5.2 Output Signals............................................................................................................................... 33
5.2.1 System Ready Signal (SRDY)............................................................................................... 33
5.2.2 Operation Ready Signal (RUN) ............................................................................................. 33
5.2.3 Positioning Completion Signal (INP) ..................................................................................... 33
5.2.4 Homing Completion Signal (ORGR)...................................................................................... 34
5.2.5 Torque Limiting Signal (TLR) ................................................................................................. 34
5.2.6 Alarm/Fault Signal (ALM)....................................................................................................... 35
5.2.7 Feedback Pulse Output Signals (AFB, /AFB, BFB, /BFB, ZFB, /ZFB, GND)........................ 35
6. Parameters ......................................................................................... 36
6.1 Parameter Configuration............................................................................................................... 36
6.2 Parameter List............................................................................................................................... 36
6.3 Parameter Setting ......................................................................................................................... 40
6.3.1 Basic Settings ........................................................................................................................ 40
(1) Electronic Gear ...................................................................................................................... 40
(2) Command Pulse Input Mode ................................................................................................. 42
6.3.2 Application Settings ............................................................................................................... 43
(1) PIO Function Setting Flag...................................................................................................... 43
(2) Communication Speed........................................................................................................... 44
(3) Flag for Setting Function at Stop ........................................................................................... 44
(4) Software Stroke Limit............................................................................................................. 44
(5) Ball Screw Lead Length......................................................................................................... 46
(6) Motor Type............................................................................................................................. 46
(7) Encoder Type......................................................................................................................... 47
(8) Number of Encoder Pulses.................................................................................................... 47
(9) Axis Operation Type............................................................................................................... 48
(10) In-Position Width.................................................................................................................... 48
(11) Deviation Error Output Range ............................................................................................... 49
(12) Homing Pattern Code ............................................................................................................ 49
(13) Speed Command Value at Homing........................................................................................ 50
(14) Acceleration Command Value at Homing.............................................................................. 51
(15)
Offset Amount at Homing....................................................................................................... 51
(16) Homing Deviation Pulse ........................................................................................................ 52
(17) Position Control Loop Proportional Gain ............................................................................... 52
(18) Position Command Primary Filter Time Constant.................................................................. 53
(19) Position Feed-Forward Gain .................................................................................................. 53
(20) Jog Acceleration Default Value.............................................................................................. 54
(21) Jog Deceleration Default Value ............................................................................................. 55
(22) Jog Speed Default Value ....................................................................................................... 56
(23)
Maximum Speed at Incomplete Homing................................................................................ 57
(24)
Maximum Acceleration Value................................................................................................. 58
(25)
Maximum Deceleration Value ................................................................................................ 59
(26) Soft Limit Actual Position Margin ........................................................................................... 59
(27) FBP Mode (Feedback Pulse Output Mode Selection)........................................................... 60
(28) Speed Loop Gain ................................................................................................................... 61
(29) Speed Loop Integration Time Constant ................................................................................. 62
(30) Torque Filter Time Constant................................................................................................... 62
(31) Current Control Bandwidth .................................................................................................... 63
(32) Torque Limit Value ................................................................................................................. 63
6.4 Servo Adjustment.......................................................................................................................... 64
6.4.1 Control Block Diagram...........................................................................................................64
6.4.2 Adjustment 1.......................................................................................................................... 65
(1) The Host Controller is not Equipped with Acceleration/Deceleration Function or the Input
Pulse Frequency Changes Sharply....................................................................................... 65
(2) The Actual Speed does not Follow Commands Well............................................................. 66
6.4.3 Adjustment 2.......................................................................................................................... 67
(1) Shocks at Start/Stop .............................................................................................................. 67
(2) Abnormal Noise at Low Speed (Stop).................................................................................... 67
7. Troubleshooting.................................................................................. 68
7.1 Handling Problems........................................................................................................................ 68
7.2 Fault Diagnosis ............................................................................................................................. 68
7.2.1 Errors Occurring when Turning the Power Supply on.................................................................. 69
7.2.2 Errors Without Alarm Display........................................................................................................ 69
(1) The Actuator does not Operate.............................................................................................. 69
(2) Positioning is not Accurate.....................................................................................................70
(3) Abnormal Noise and Vibration are Generated....................................................................... 70
7.2.3 Alarms.................................................................................................................................... 71
(1) Alarm Levels.......................................................................................................................... 71
(2) List of Alarms ......................................................................................................................... 72
8. Operation Procedure .......................................................................... 75
8.1 Step 1............................................................................................................................................ 75
8.2 Step 2............................................................................................................................................ 76
8.3 Step 3............................................................................................................................................ 77
8.4 Step 4............................................................................................................................................ 78
9. PC Software (PDR-101-MW).............................................................. 79
9.1 Before Using the PC Software ...................................................................................................... 79
(1) Checking Accessories............................................................................................................79
(2) Preparation (Operating Environment).................................................................................... 79
(3) Installing the Software............................................................................................................ 80
(4) Starting the Software.............................................................................................................. 80
9.2 Checking Connection.................................................................................................................... 81
9.3 Main Window................................................................................................................................. 81
9.3.1 Operations from the Main Menu ............................................................................................ 82
(1) File Menu (F).......................................................................................................................... 82
(2)
View Menu (V) ....................................................................................................................... 82
(3)
Parameter Menu (P) ..............................................................................................................82
(4) Monitor Menu (M) .................................................................................................................. 83
(5) Driver Menu (D) ..................................................................................................................... 83
(6) Tool Menu (T)......................................................................................................................... 83
(7) Window Menu (W) .................................................................................................................83
(8) Help Menu (H)........................................................................................................................ 84
9.3.2 Operations from the Toolbar .................................................................................................. 84
9.4 Edit Parameter Window ................................................................................................................ 85
9.4.1 Explanation About the Edit Parameter Window..................................................................... 85
9.4.2 Saving Parameters and Completing Editing.......................................................................... 86
(1) Saving Parameter Data Currently Being Edited to a File ...................................................... 86
(2) Transferring Parameter Data Currently Being Edited to the Driver ....................................... 86
(3) Restarting the Driver (Software Reset).................................................................................. 86
(4) Completing Editing Parameters............................................................................................. 86
9.5 Monitor .......................................................................................................................................... 87
9.5.1 Status Monitor Window.......................................................................................................... 87
9.5.2 Error List Window .................................................................................................................. 89
9.6 Driver............................................................................................................................................. 90
9.6.1 Jog Movement Window ......................................................................................................... 90
(1) Current Position, Alarm Code and Mode Display Panel ........................................................ 90
(2) Jog Operation Panel.............................................................................................................. 91
(3) Button Panel .......................................................................................................................... 91
(4) Processing when Closing the Jog Movement Window.......................................................... 92
9.6.2 Re-Connection....................................................................................................................... 92
9.6.3 Memory Initialization.............................................................................................................. 93
9.6.4 Software Reset ...................................................................................................................... 93
9.7 Tool................................................................................................................................................ 94
9.7.1 Environment Setting .............................................................................................................. 94
9.8 Help............................................................................................................................................... 97
9.8.1 Version Information................................................................................................................ 97
1. Overview
This product is a pulse-train input type controller for actuators manufactured by IAI.
It allows controls according to the command signals from the positioning control function of a host
controller (PLC).
1.1 Features
Q Dedicated Homing Signal
P-Driver supports our proprietary stroke end push homing operation. This function allows automatic
homing without using complex sequences or external sensors.
Q Brake Control Function
The power supply of the electromagnetic brake is supplied to the controller, separately from the main
power supply. Since the brake is controlled by the controller, there is no need to program a sequence.
Moreover, the electromagnetic brake can be released at any point after the main power supply is cut off.
Q Torque Limiting Function
The actuator torque can be limited using external signal (via parameter setting), and a signal is output
when the specified torque is reached. With the use of this function, push operation and press-fitting
become possible.
Q Feed-Forward Control Function
Response can be raised under certain conditions, such as when the load inertial ratio is high.
Increasing this parameter setting decreases the deviation (difference between the position command
and the position feedback), thus resulting in improved response.
Q Position-Command Primary Filter Function
Soft start and stop are possible even if acceleration/deceleration is not specified in the command pulse
input.
Q Feedback Function
Position detection data can be output as pulse trains (differential output). This enables reading of the
current position in real time from the host controller.
1
1.2 Name and Function of Each Part of the Controller
(5) Input connector for
electromagnetic-brake power supply
(4) Input connector for actuator sensor
(optional)
(3) Motor connector
(2) Connector for regenerative
resistance unit (optional)
(1) Input connector for main power
supply
(1) Input connector for main power supply
(2) Connector for regenerative resistance unit
(3) Motor connector
(4) Input connector for actuator sensor
(5) Input connector for electromagnetic-brake power supply
Connects the power supply for electromagnetic brake.
(6) Status indicator (LED)
(7) Communication connector
(8) I/O signal connector
(6) Status indicator LED
RUN (green)
RDY (green)
Connects the power supply.
Connects a regenerative resistance unit (optional).
Connects the actuator’s power cable.
Connects cables from the actuator’s sensors such as
LS, CREEP and OT (optional).
(An electromagnetic brake requires an external power
supply.)
Used to monitor the controller’s operating condition.
RDY (green): Indicates that P-Driver is operating
RUN (green): Indicates that the servo is on.
ALM (red): Indicates that an alarm is generated.
ENC (yellow): Indicates that the encoder is
Connects the PC software cable.
Connects the control I/O signals.
ALM (red)
ENC (yellow)
(7) Communication connector
(8) I/O signal connector
(9) System setting switch
(10) Brake release switch
(11) Encoder brake connector
normally.
disconnected or not connected.
2
(9) System setting switches
Used to change the encoder voltage and boot mode (for remote start).
(The rotary switch is used for adjustment by the manufacturer.)
System setting switches
Switch Symbol Function
1 /BTRT Switch for changing boot mode (Set to OFF.)
2 ENCV2 Switch for adjusting encoder power-supply voltage 2
3 ENCV1 Switch for adjusting encoder power-supply voltage 1
4 - Not used (Set to OFF.)
[Settings of switches for changing encoder power-supply voltage]
Set these switches according to the cable length of the encoder.
Switch
2 3
ENCV2 ENCV1
Cable length
[m]
Output voltage
[V]
See the table below
for the setting.
OFF OFF - 5.15
OFF ON L < 15 5.45
ON OFF
ON ON
15 ≤ L < 25
25 ≤ L < 30
(10) Brake release switch
Used to forcibly release the brake.
(11) Encoder brake connector
Connects the actuator’s encoder/brake cable connector.
5.75
6.05
3
1.3 How to Read the Model Specification
PDR I 100 B 1 P
<Basic model>
<Encoder type>
I: Incremental
<Motor capacity of actuator>
20: 20 W
30: 30 W
60: 60 W
100: 100 W
150: 150 W
200: 200 W
400: 400 W
600: 600 W
750: 750 W
1.4 Applicable Actuators
It is possible to control the following types of actuators.
(1) RCS-SS (R)
(2) RCS-SM (R)
(3) RCS-RA55
(4) RCS-F55
(5) RCS-RB7530/7535
(6) RCS-R10I/20I/30I
(7) RCS-G20I
(8) ISP (D)
(9) IS (D)
(10) IF
(11) FS
(12) SS
(13) 12RS-30/60
(14) DS-SA4/SA5/SA6
<I/O signal specification>
Blank: NPN
P: PNP
<Power-supply voltage>
1: 100 V specification
2: 200 V specification
<Options>
Blank: None
B: Brake
C: Creep sensor
L: Limit switch
4
1.5 Options
(1) PC Software (Model PDR-101-MW)
Content: Floppy disks, PC link cable 1.5 m (Unit model CB-ST-SIO015)
Used to set P-Driver parameters, monitor jogging operation during debugging, check various signals,
and so on.
PC link cable
Taiyo Electric Wire & Cable (7-core twisted paired
cable with shield; UL/cUL compliant)
2464-1061-2A-SB-5PX24AWG
D-sub 9-pin socket:
XM2D-0901 (Omron)
Hood:
XM2S-0913 (Omron)
Controller side
XM2D-0901
Wire Color Signal No. No. Signal Color Wire
Orange with black dots RD 2 3 TXD Orange with black dots
AWG 24 x
7 cores
1 1
Orange with red dots SD 3 2 RXD Orange with red dots
ER 4 4 DTR
Yellow with black dots SG 5 5 SG Yellow with black dots
DR 6 6 DSR
RS 7 7 RTS
CS 8 8 CTS
9 9
(2) External I/O Cable (Model CB-PD-PIOS020)
Content: Plug, shell and 2-m shielded cable
Use this cable for connection between I/O signals and the host device.
No connector for the host device side is provided.
Perform wiring according to the host device to be used.
Plug: 10126-3000VB (Sumitomo 3M)
Shell: 0326-52A0-008 (Sumitomo 3M)
10126-3000VE
Wire Color Signal No.
0.2 sq.,
soldered
Black COM-A 1 Black
White/black COM-A 2 White/black
Red SRDY 3 Red
White/red RUN 4 White/red
Green INP 5 Green
White/green ORGR 6 White/green
Yellow TLR 7 Yellow
White/yello w ALM 8 White/yellow
Brown SON 9 Brown
White/brown RES 10 White/brown
Blue ORGC 11 Blue
White/blue TL 12 White/blue
Gray CSTP 13 Gray
White/gray COM-B 14 White/gray
Orange NP 15 Orange
White/orange /NP 16 White/orange
Purple PP 17 Purple
White/purple /PP 18 White/purple
Light green AFB 19 Light green
White/light green /AFB 20 White/light green
Pink BFB 21 Pink
White/pink /BFB 22 White/pink
Sky blue ZFB 23 Sky blue
White/sky blue /ZFB 24 White/sky blue
White GND 25 White
Black/white
Shield is connected to a cable clamp Shield
GND 26 Black/white
Sunlight SX (N), 13P x 0.2 sq. (Taiyo Electric Wire & Cable)
1.5 m
2 m
PC side
XM2D-0901
Shield
D-sub 9-pin socket:
XM2D-0901 (Omron)
Hood:
XM2S-0913 (Omron)
No connector at end
AWG 24 x
7 cores
Host device side
5
♦
(3) Regenerative Resistance Unit (Model REU-1)
When the actuator is operating, the motor (drive unit) uses supplied electric energy to rotate. On the
contrary, when it decelerates, the motor acts as an electric generator that supplies current back to the
controller. This is called a regenerative current.
In the case of a vertical application, a large regenerative current will flow into the controller at descending.
P-Driver has a built-in regenerative resistance, but in the case of vertical applications, an additional
regenerative resistance unit is required, which is sold separately.
♦ Regenerative resistance unit specification
Model REU-1
Unit dimensions W34 mm x H195 mm x D126 mm
Unit weight 0.9 kg
Ratings of built-in regenerative resistance
Accessory
♦ Installation conditions and quantity
A regenerative resistance unit is required only in the case of vertical applications. It is not required for
horizontal applications.
Motor wattage of vertical axis Quantity
0~150 W Not required
~200 W 1 unit is required.
~400 W 1 unit is required.
~600 W 1 unit is required.
~750 W 2 units are required.
Caution
z Alarms are not detected.
z Thus, excessive heat may be generated if the number of regenerative resistance units is insufficient.
Exercise caution.
♦ External dimensions
5
φ 5
17.4
3.4
(16.6)
126
10
186
195
175
R2.5
(4)
6
17.4
(10)
(18.8)
220 Ω 80W
Controller link cable (1 m)
Model CB-ST-REU010
Connection method
Controller
RB
Regenerative resistance unit
First unit
Controller link cable
Second unit
6
2. Specification
2.1 Specification List
Actuator motor capacity (W) 20 30 60 100 150 200 400 600 750
Power-supply capacity
(W) 34 42 100 150 210 270 520 770 1000
(VA) 57 70 160 240 350 450 870 1300 1600
100 V specification: single-phase, 100 to 115
Input power supply
VAC ±10%, 50/60 Hz
200 V specification: single-phase, 200 to 230 VAC ±10%, 50/60 Hz
Control method Sine wave PWM, vector current control
Position detection method Incremental encoder
Braking method Regenerative resistance
Control mode Position control via pulse-train input
Maximum input pulse
frequency
Command pulse
magnification
(electronic gear:
Positioning completion
Function/performance
width
A
B
Power supply for I/O signal
interface
Power supply for
electromagnetic brake
Max. 500 kpps (differential) / Max. 200 kpps (open-collector)
A, B = 1 to 4096
A
1
)
<
50
50
<
B
(parameter setting)
1
1 to 4096 pulses (parameter setting)
24 VDC ±20%, 0.8 A (supplied externally)
24 VDC ±20%, 1 A (peak value) (supplied externally)
Communication function RS232C (for dedicated PC software)
Protection functions
Operating
temperature/humidity
Storage temperature
Motor overvoltage, overcurrent, abnormal driver temperature, encoder
error, motor overload, etc.
0 to 40°C, 85% RH or less (non-condensing)
-20 to 70°C (non-condensing)
-
Operating ambience Free from corrosive or flammable gases, oil mist or dust
conditions
Environmental
Durability/vibration 4.9 m/s2 (0.5 G)
Withstand voltage 1500 VAC for 1 minute (1000 VAC for 1 minute with actuator connected)
Protection structure Open, forced air cooling (IP20)
Weight 1.2 kg
7
2.2 External Dimensions
129.1
44.1
88.2
φ 5
5
5
5
184
194
8
3. Installation and Noise Prevention
Please pay attention to the controller’s installation environment.
3.1 Installation Environment
a. Avoid blocking air vents for cooling when installing and wiring the controller. (Insufficient ventilation
prevents the controller from achieving full performance and may also cause failure.)
b. Prevent foreign objects from entering the controller through the air vents. Moreover, be aware that the
controller is neither dust-proof nor water (or oil)-proof; avoid using it in dusty environments or
locations where oil mist and cutting fluid may be scattered.
c. Avoid subjecting the controller to heat radiation from large heat sources such as direct sunlight or
heat-treatment furnaces.
d. Use the controller in an environment with an ambient temperature of 0 to 40°C and a humidity of 85%
or less (no condensation), and free from corrosive or flammable gases.
e. Use the controller in an environment free from external vibration and impact.
f. Avoid inducing electric noise to the controller unit and wiring cables.
3.2 Supply Power
Depending on the type of controller, it is possible to select the supply power from 100 VAC or 200 VAC.
3.3 Noise Prevention and Grounding
(1) Wire and Power Supply
Power-supply terminal block PE is protective ground; perform D-class (third-class) grounding.
Moreover, use electric wires with a thickness of 0.75 mm
power-supply wire used.
D-class grounding
(protective ground)
Power supply 100/200 VAC
2
(AWG18) or more, and thicker than the AC
PE
1
L
2
3
N
9
(2) Grounding for Noise Prevention
a. It is necessary to ground the controller to prevent noise, regardless of whether it is configured as a
100 or 200 VAC system.
b. General precautions on wiring method
Separate the wiring of the controller from strong electric lines such as the power circuit. (Do not bind
wires together, and do not place in the same duct.)
Consult IAI’s Technical Service Department or Sales Technology Department if you need longer
cables for motor or encoder wiring.
Connect the controller unit by affixing it to the metal enclosure directly with screws.
100/200 V
controller
Protective ground
1
2
(AC power supply)
3
Make the ground wire as
thick and short as possible.
Metal
enclosure
10
←
(3) Protecting Against Noise Emitting Sources
There are many types of noise emitting sources, but the most familiar ones when building a system
include solenoid valves, magnet switches and relays. The controller can be protected against noise
from such sources by the following actions:
a. AC solenoid valves, magnet switches and relays
Action: Mount a surge killer in parallel with each coil
b. DC solenoid valves, magnet switches and relays
Action: Mount a diode in parallel with each coil. Determine the capacity of the diode according to the load
capacity.
Point
Connect the surge killer to each coil with the shortest
possible wiring.
When it is connected to a terminal block or similar,
the effect is lost if the distance to coil is large.
Careful attention should be paid in the case of DC current; if
the polarity of the diode is mistaken, the diode, internal circuitry
of the controller and/or DC power supply may be destroyed.
11
3.4 Heat Dissipation and Installation
Design the size of the control panel, layout of the controller installation and cooling method so that the
peripheral area of the controller is 40°C or less.
Install the controller vertically on a wall. The controller is cooled by forced ventilation (a jet on the top part).
Observe this direction when installing and ensure a clearance of 100 mm or more above the controller
and 50 mm or more below the controller.
If two or more controllers are installed in parallel, the ambient temperature can be made even by
mounting an additional fan to ensure air circulation in the air above the controllers.
Moreover, ensure a clearance of 100 mm or more between the front side of the controller and wall
(cover).
Ensure a clearance between controllers that allows easy installation and removal of individual controllers,
regardless of the number of controllers.
Wind direction
Fan
100 mm or more
100 mm
or more
50 mm or more
Ventilation
12
A
A
4. Wiring
4.1 Configuration
[Parts to be prepared by
Single-phase AC power supply
Line filter
Since the PWM control circuit of this
product generates higher harmonics
due to switching, radiation noise and
conduction noise may influence
peripheral devices connected to the
same power supply. In such cases,
mount a line filer.
the customer]
100~115 V 50/60 Hz
200~230 V 50/60 Hz
Power-supply breaker
Switches the power
supply on/off and
prevents damages due
to short-circuit current.
Electromagnetic contact
Used when disconnecting
this product from the
power supply, such as at
emergency stop.
C reactor
Used when the
power-supply capacity is
large, in order to control
voltage fluctuations and
higher harmonics.
ctuator
[Parts to be prepared by
the customer]
General-purpose PC
The PC software dedicated for
Motor cable
Encoder cable
LS cable (optional)
Regenerative resistance unit
(optional)
P-Driver allows parameter setting
and operation adjustment.
Brake power supply
24 VDC, 1 A
External (host) controller
P-Driver supports various
controllers of pulse-train output
type.
Power supply for I/O signals
24 VDC 0.8 A
Caution
z Separate the power supply for
the brake from the power supply
for the I/O signal interface.
13
/
/
/
/
/
/
/
/
A
r
4.2 Connection Diagram
The following figure shows a connection diagram of the P-Driver unit.
(1) Standard
MS
Power supply:
Single-phase, 100 VAC
Single-phase, 200 VAC
Brake power supply: 24 VDC
(for actuator with brake)
0 VDC
(NPN specification)
24 VDC
(PNP specification)
Power supply for
I/O signal
interface: 24 VDC
Connect the PIO shielded cable to the
connector shell. An optional external I/O
cable is already connected.
L
N
PE
+
BK
-
PIO
17 PP
18/PP
15 NP
16/NP
9 SON
10 RES
11 ORGC
12 TL
13 CSTP
14 COM-B
1 COM-A
2 COM-A
ORGR 6
U
V
W
PE
ENC
A 1
A 2
B 3
B 4
Z 5
Z 6
SD 7
SD 8
BAT 9
BAT 10
VCC 11
GND 12
BKN 13
BKP 14
FG 15
PIO
AFB 19
AFB 20
BFB 21
BFB 22
ZFB 23
ZFB 24
GND 25
GND 26
SRDY 3
RUN 4
INP 5
TLR 7
ALM 8
ctuato
Feedback pulse
output (differential)
24 VDC
0 VDC
Load
Load
゛
Load
゛
Load
゛
Load
゛
Load
゛
(NPN specification)
(PNP specification)
14
A
r
(2) Option
Regenerative
resistance unit
RB+ RB-
PE
CREEP
24V
LS
OT
RSV
N
ctuato
15
4.3 Power-Supply Input Interface
Connect the power supply specified in 2.1, “Specification List,” to P-Driver.
It must be possible to cut off the AC power supply via an electromagnetic contact in case of an emergency
stop.
(1) Commercial Power
a. 100 V specification: single-phase, 100 to 115 VAC ±10%, 50/60 Hz
b. 200 V specification: single-phase, 200 to 230 VAC ±10%, 50/60 Hz
List of AC power-supply input connector terminals (Phoenix GMSTB2.5/3-GF-7.62 DIP)
Symbol Function
L
N
PE
* Connectors (plugs) are standard accessories.
Main power-supply input terminals
Ground terminal; perform D-class (third-class) grounding or higher.
16
(2) Emergency Stop
It must be possible to cut off the AC power supply via an electromagnetic contact in case of an
emergency stop.
The following figure shows a reference circuit.
+ Turn the forced stop signal (CSTP) on by turning RY off.
When CSTP is turned on, the forced stop processing is performed and the servo is turned off.
Note that if the timer (T) is set short, the drive unit may be cut off before the servo is turned off and the
motor is placed in the free-run status and may become unable to stop. For this reason, wait until
sufficient time has elapsed to allow the motor to stop and then cut off the power to the drive unit (be
careful with the setting of T).
Emergency stop release switch Emergency stop switch
Commercial power
PB 1
RY
RY
MS
RY
Input an alarm/fault signal (ALM) (ON in normal
circumstances).
In this circuit, when PB 1 is turned on and the power is
supplied via MS, MS is self-maintained unless P-Driver
enters an alarm status.
MS is kept turned on unless EMG PB is pressed or
P-Driver enters an alarm status.
T
Input an operation ready signal (RUN).
MS
T
P-Driver
MS
L
N
(100 msec)
* Reference value
17
(3) Electromagnetic Brake Power-Supply Input
This input is required when the actuator has an electromagnetic brake.
Connect a dedicated external power supply.
24 VDC ±20% 1.0 A (peak value)
Do not use the same power supply for the brake power supply as for the I/O signals.
List of electromagnetic brake power-supply input connector terminals (Phoenix MC1.5/2-GF-3.81 DIP)
Symbol Function
BK
* Connectors (plugs) are standard accessories.
+
Electromagnetic brake power-supply input terminals
-
4.4 I/O Signals
Connect the control I/O signals to the external (host) controller.
List of DI/DO interface connector terminals (3M 10226-52A2JL)
Signal
classification
Pin
No.
Symbol Signal name Function
Power
supply
Sequence
signal output
1
COM-A
2
3 SRDY System ready
4 RUN
5 INP
6 ORGR
7 TLR Torque limiting
8 ALM Alarm
Power-supply
common (+)
Operation
ready
Positioning
completion
Homing
completion
Power supply common for external I/O signals.
Connect this terminal to the + side of a 24 VDC
supply. (Pin No. 1 and 2 are internally connected.)
Turns on when the initialization is completed
normally and control of P-Driver is enabled after the
power supply is turned on. Synchronized with the
RDY LED located on the front side of the controller.
Turns on when the servo is turned on and operation
of the servo motor is enabled. Synchronized with the
RUN LED located on the front side of the controller.
Turns on when the robot enters the set in-position
range. (The in-position range is set via parameters.)
Turns on when homing is complete, as indicated by
the ORGC input.
Turns on when the torque reaches the set torque
limit value while TL is on. (The torque limit value is
set via parameters.)
Turns off when a protection circuit (function) is
actuated and the base current is interrupted. This
signal is normally turned on after the power supply is
turned on. Synchronized with the ALM LED located
on the front side of the controller.
The ALM LED is lit in case of an alarm.
18
Signal
classification
Pin
No.
Symbol Signal name Function
9 SON Servo ON
Operation of the servo motor is enabled when this
signal is turned on. The servo motor is placed in
the free-run status when this signal is turned off.
In the case of an actuator with a brake, the brake
is released when this signal is turned on.
If this signal is turned off during operation, forced
stop processing is performed and the motor is
placed in the free-run status. In the case of an
actuator with a brake, the brake is applied at the
same time as the motor is placed in the free-run
status.
Sequence
signal
input
Power
supply
Command
pulse
input
10 RES Alarm reset Alarms are reset at the rising edge of this signal.
11 ORGC
Homing
command
Homing operation starts at the rising edge of this
signal.
The torque limit value set in the parameter
becomes valid when this signal is turned on. To
perform push operation, turn this signal on before
starting the positioning of the actuator or in the
12 TL
Torque limit
selection
middle of the positioning operation.
When this signal is turned on, the robot
decelerates to a stop at the forced stopping torque
and the servo is turned off.
Power-supply common for external I/O signals.
Connect this terminal to the - side of a 24 VDC
supply.
Inputs pulse-train for positioning command.
Open-collector method: Max. 200 kpps
13 CSTP
14 COM-B
15 NP
External
forced stop
Power-suppl
y common (-)
Differential receiver method: Max. 500 kpps
16 /NP
Pulse-train
input
17 PP
The command pulse mode can be chosen from
90-degree phase shifted signal (phases A/B, in
quadrature), pulse-train + forward/reverse signal,
and forward/reverse pulse, and input logic mode
can be selected from positive logic and negative
logic for each of the above.
Moreover, the amount of unit movement per pulse
can be set by an electric gear. (The command
18 /PP
pulse input mode and electric gear settings are
specified using parameters.)
19
Signal
classificati
on
Feedback
pulse output
(differential)
Pin
No.
19 AFB +A
20 /AFB -A
21 BFB +B
22 /BFB -B
23 ZFB +Z
24 /ZFB -Z
Symbol Signal name Function
Outputs position detection data as a pulse train
(differential).
The output pulse mode can be chosen from
90-degree phase shifted signal (phases A/B, in
quadrature), pulse train + forward/reverse signal,
and forward/reverse pulse, and output logic mode
can be selected from positive logic and negative
logic for each of the above. (The output pulse
mode is specified using parameters.)
The resolution is determined by the electric gear
ratio of the command pulse input. (The position
detection data is output with the same resolution
as the command signal.)
25
GND
26
* Connectors (plugs and shells) are standard accessories.
* Optional external I/O cables (CB-PD-PIOS020) are prepared.
Caution
z Note that the actuator moves in the negative direction with a forward pulse (forward for the motor) and
in the positive direction with a reverse pulse (reverse for the motor). (Opposite applies to folded motor
type actuators.)
z When considering the forward/reverse direction, pay attention to the settings of the host controller or
connection of PP and /PP as well as NP and /NP.
* The rotation direction of the motor is indicated by setting CCW to forward, as seen from the axis edge
of the load side.
Reference
potential
Line driver ground line for feedback pulse output
(Pins 25 and 26 are internally connected.)
20
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