Intelligent Actuator Inc (IAI) Q&A

Submitted by Automation Engineering Staff
Who is IAI?

Intelligent Actuator Inc (IAI) is a world leader in the design and manufacture of off-the-shelf single and multi axis servo positioning systems and SCARA robots. IAI provides a broad range of Intelligent Actuator brand actuators ranging in stroke from 50 millimeters to 3 meters in length with speeds up to 1,500 mm per second and payloads up to 80 kg. New RoboCylinder model actuators offer closed loop performance in the price range of pneumatics. IAI also offers class 10 cleanroom actuators and robots and ESD-rated actuators for specialty applications. Ease of programming and superior design of these off-the-shelf systems allows for extremely fast implementation and system start-up. Increase your throughput and productivity with IAI servo actuators! Intelligent Actuator Inc IAI is an industry leader in "Green" Automation. Automation Controls is proud to be IAI's largest hi-tech solution provider in the United States.
 
DS Controller FAQ

Q: The DS has been running for a while, but it shows 'reS' on the front of the display now all the time. All the I/O connections have been verified and everything is plugged in.
 
A: It's quite possible that the internal surface-mount fuse has blown. We usually have replacement fuses in stock, but the replacement must be done as it is an internal repair.
 
Q: We unpacked the DS and tried to run the it both with the teach pendant and the software, but the display is constantly in reset ('reS').
 
A: You need to supply power to your I/O to run the DS because the reset input defaults to an "on" state, sending the controller into reset.
 
Q: If we have extra controllers, and a list of parameters that go with each of the DS units that we own, can we simply swap out controllers and change the parameters?
 
A: Yes and no. The controller for the Medium and High speed DS units is the same controller; interchangeable with a simple parameter change and jumper switch. The controller for the Low speed DS units is not interchangeable with the Medium/High at all.
 
Q: Is the DS available with PNP I/O?
 
A: Yes. As with all of our other products, the only wiring that changes on the I/O is the power inputs to the I/O. The power (+24V) and common (0V) are opposite on the PNP. The style of I/O needed must be specified at the time the DS is ordered. The customer will be charged for the repair if the I/O is changed after the fact.
 
MSEL Controller FAQ
 
Q: I've got the SelWin v4.xx software, can I program the MSEL with this?
 
A: No. The MSEL has its own dedicated software. It's MS DOS-based and the final release version of this software was v2.08, released in 11/93.
 
Q: I've used some of your other controllers and all had a limit switch connector on the controller. Where is the limit switch connector for the MSEL?
 
A: The limit switch connection is made through the I/O connector on pins 28 (for X axis), 4 (for Y axis), 29 (for Z axis) and 5 (for Theta axis). There is no dedicated input terminal for the limit switch on the controller.
 
Q: What are a few parts that would be good to have on hand?
 
A: Keeping an extra memory card on hand containing backup information is not a bad idea. These memory cards have been discontinued by the original equipment manufacturer, so Intelligent Actuator can not obtain them. For production-critical, heavy-load applications, the purchase of either backup driver boards or a controller is a good idea as well.
 
Q: I need a replacement driver board for a 60W DC motor. What info do you need?
 
A: The MSEL has three different 60W driver boards. One is for the Japan Servo motor, one is for the Yaskawa motor and one is for the Tamagawa motor. In the case of a 60W motor, check to see the part number on the motor itself and possibly, the brand name. Improperly matched driver boards will not function and may cause damage.
 
Robo Cylinder Controller FAQ

Q: We powered up the Robo Cylinder, but we can't run it with either the software, teach pendant or through the I/O. On the software and teach pendant, we get a '20D error'.
 
A: In order to run the Robo Cylinder, the 'Sudden Stop' input must be on. It's a normally-closed input designed to stop the Robo Cylinder when tied to a door latch, light curtain, etc., and then continue motion after the input turns back on.

Q: When controlling the unit in point-to-point mode using the 'Command Position' inputs, we were able to move to the first position, but did not see the Positioning Complete Output at the end of the move.
 
A: Make sure that you turn off the Start input after the unit begins to move. You will not see the Positioning Complete Output turn on until the Start input is off.

Q: Do I have to wait for the Robo Cylinder to reach the final position in point-to-point mode before I tell it to move to another position?
 
A: No. The Robo Cylinder can move to the next point before it reaches the first. Simply dial in the new Command Position inputs and pulse the start input.

Q: I'm a bit confused on what happens when the RCP rod type torques out in push mode and when it strokes out in push mode. What happens on the outputs?
 
A: When the Rod Type torques out, the position complete output AND the complete position outputs turn on. When the Rod Type strokes out, ONLY the complete position outputs turn on indicating what position it's at.

Q: Is the Robo Cylinder available with PNP I/O?
 
A: Yes. The voltage level is different to turn on inputs and when outputs are on..

Q: With some controllers, you have to re-home after using the dedicated e-stop inputs. Do you have to re-home the Robo Cylinder after e-stop?
 
A: No. The Robo Cylinder is unique in that the e-stop terminal does not shut down the encoder or main CPU. The only time you have to re-home is if you have a major axis fault or cycle power on the controller.
 
IH SCARA Controller FAQ
 
Q: In the Controller Operating Manual, I noticed that there is an emergency stop contact input listed on pin 2 of the I/O diagram. I tried to use this, but it doesn't seem to be working.
 
A: That is actually a typographical error. There is no emergency stop control through the I/O, only via the front of the controller, the back terminal, or the RS232 Cable.
 
Q: We've got a few other machines running on the same 220VAC line as the IH-SCARA. When we're in full production sometimes the IH-SCARA will fault out 'A7' on all 4 axes and the z-axis will drop.
 
A: We recommend that the IH-SCARA controller is powered by a dedicated constant-voltage transformer. If one is not available, please use a dedicated 220VAC line that runs at a voltage level of 200/220VAC +/- 10%. The A7 and z-drop is due to a quick dip in voltage level forcing the controller to think the motors are still on, even though the dip cut power.
 
Q: We've been running production now for about 14 months at a very low payload and about 60% speed. We've followed the maintenance procedure for re-greasing the ballscrew, but the z-axis has just lately started to "squeal" when it moves up.
 
A: When the IH-SCARA is shipped from the factory, the driver parameters are configured based on maximum payload and maximum speed. These work for most people most of the time. However, after the IH-SCARA has settled in to a routine, it may not need all the power it receives for the driver, so the axes may act strange. The parameter change routine is available through us.
 
Q: What's the difference between wiring for the NPN I/O card and PNP IO card?
 
A: The main difference is that the power connection for Power (+24V) and Common (0V) are switched. On the NPN I/O card, the power connection is on pin 1A (Brown) and the common is on 25B (Black). The PNP card is the exact opposite from the NPN card.
 
Q: Our system has grown in size and we're considering the option of a vision system. We didn't purchase the original system with the 2ch RS232c option installed. Is this something that we can install ourselves?
 
A: Expansion I/O and 2ch RS232 cards can be added in the field. Anything above and beyond this, however, would require an IA Engineer to modify the controller in-house or on-site.
 
SEL-A/B Controller FAQ
 
Q: Currently we're running a 4-axis system (X, Y, Z, and Rotary) and would like to add a 60W fifth axis for part indexing. We've got a SuperSEL A controller. Is this field-upgradeable to five axes?
 
A: No. The SuperSEL A only handles up to 4 axes of control. The next controller up is a SuperSEL B and can handle up to 8 axes of control. The frame of the controller is larger and would require 75% replacement.
 
Q: We were running production and the controller's display blanked out, the servos turned off and the outputs to our solenoids shut down. What happened?
 
A: If all these symptoms showed up at the same time, the incoming line voltage fuse has probably failed. The fuse is accessible from the back of the controller (SEL B) or in-line with the power connection (SEL A). Before powering the controller back up, be sure to check the incoming line voltage level for abnormalities.
 
Q: We replaced a down controller with a backup controller. The backup had all the same programs, points and parameters as the first. We put the backup in and it acted like the memory was empty.
 
A: There is a Ni-Cd battery that backs up all the information inside the controller while it is powered down. If the backup controller has been powered down for over 3 months, chances are the data is lost. Since the battery is rechargeable, simply leave the controller powered up and the battery will recharge itself in 2-3 days.
 
Q: In addition to the SuperSEL A running the AS series, we've got newer SuperSEL G controllers running IS actuators. One of our brake boxes for the "A" has failed. Can I take a spare SuperSEL G brake box and use it for the SuperSEL A?
 
A: No. The brake box for your SuperSEL A is a DC Brake Box, the brake box for the SuperSEL G is an AC Brake Box. The two are not interchangeable.
 
SEL-E/G Controller FAQ
 
Q: The actuators have been connected, the I/O powered up, the brake connected and creep sensor plugged in, When we try to home the system, we come up with an 'A4' error on the controller.
 
A: Check to see that the slide is not past the creep sensor in the direction of the homing hard stop. For example, if your creep sensor is installed on the motor end, and the slide is between the sensor and the motor-end hard stop, you'll get the A4 error.
 
Q: The actuators have been connected, the I/O powered up, the brake connected and limit switches plugged in, When we try to home the system, we come up with an 'EG' error on the controller.
 
A: Check to see that the slide is not past either limit switch sensor. As long as the slide is between the two limit switch sensors, you'll be able to home.
 
Q: We've got a single-axis 200W AC SuperSEL E controller. We don't have a brake on the axis, but there is an extra connector on the controller labeled 'RB'. We couldn't find what plugs in to that connector, so we ran the units. After a while, the 'A1' error shows up on the front of the controller.
 
A: The 'RB' connector stands for "Bleeder Resistor" or "Regenerative Box". Without the external regenerative box connected to your controller, the A1 error will appear showing "over regenerative current" on the driver module. This external box bleeds the extra voltage away from the controller. If a brake were present, the bleeder resistor is included in the brake box.
 
Q: What's the difference between wiring for the NPN I/O card and PNP IO card?
 
A: The main difference is that the power connection for Power (+24V) and Common (0V) are switched. On the NPN I/O card, the power connection is on pin 1A (Brown) and the common is on 25B (Black). The PNP card is the exact opposite from the NPN card.
 
Q: The system will run fine for a while, but when our ultrasonic welding unit fires up, the controller's display blanks out and the program "freezes" up.
 
A: You may have a noise problem. The ground of your I/O cable must be tied independently to the main ground, and not linked to an external device's ground. If this is the case, make sure you have DC diodes installed across the coils of your DC relays, or if you have AC relays, an RC snubber. Better shielding of the I/O cable or re-routing may also be needed.
 
Q: Is it possible to have both the limit switch option and creep sensor option on the same controller?
 
A: No. Internally to the controller there exists no circuitry that would allow for this combination to occur. The parameters are set up to accept either creep or limit switch, not both.