IAI PS241 User manual

PS241/PS242
24V Power Supply
Instruction Manual
Fourth Edition

Please Read Before Use
Thank you for purchasing our product.
This Instruction Manual describes all necessary information to operate this product safely such as the
operation procedure, structure and maintenance procedure.
Before operation, read this manual carefully and fully understand it to operate this product safely. The
enclosed DVD in this product package includes the Instruction Manual for this product.
For the operation of this product, print out the necessary sections in the Instruction Manual or display
them using the personal computer.
After reading through this manual, keep this Instruction Manual at hand so that the operator of this
product can read it whenever necessary.
[Important]
This Instruction Manual is original.
 TheproductcannotbeoperatedinanywayunlessexpresslyspeciedinthisInstructionManual.
IAIshallassumenoresponsibilityfortheoutcomeofanyoperationnotspeciedherein.
Information contained in this Instruction Manual is subject to change without notice for the purpose of
product improvement.
If you have any question or comment regarding the content of this manual, please contact the IAI
salesofcenearyou.
Using or copying all or part of this Instruction Manual without permission is prohibited.
The company names, names of products and trademarks of each company shown in the sentences
are registered trademarks.

Table of Contents
Safety Guide........................................................................................................ 1
Precautions in Handling....................................................................................... 7
1. Name and Function of Each Part.................................................................. 9
2. RDY Display and RDY Output Signal.......................................................... 11
3. Product Check............................................................................................. 12
3.1 Parts (The option is excluded.)......................................................................12
3.2 Instruction Manuals related to this product,
which are contained in the instruction manual (DVD)...............................12
3.3 How to read the model plate..........................................................................12
3.4 How to read the model No.............................................................................12
4. BasicSpecications .................................................................................... 13
5. External Dimensions ................................................................................... 14
6. Installation Environment.............................................................................. 15
7. Installation and Noise Elimination ............................................................... 16
8. Output Voltage ............................................................................................ 18
9. Protective Functions.................................................................................... 19
10. Parallel Operation........................................................................................ 20
11. Simple Troubleshooting............................................................................... 21
Appendix 1......................................................................................................... 22
Relation of Actuator and Power Supply Current
Output Current for When Connecting Multiple Power Supply Units
Appendix 2......................................................................................................... 30
Determination for Number of Connectable Units
How to Calculate Power Supply Capacity
Warranty Period and Scope of Warranty........................................................... 32
Change History.................................................................................................. 33

1
Safety Precautions for Our Products
The common safety precautions for the use of any of our robots in each operation.
Safety Guide
"Safety Guide" has been written to use the machine safely and so prevent personal injury or property
damage beforehand. Make sure to read it before the operation of this product.
No. Operation
Description Precautions
1 Model Selection ●Thisproducthasnotbeenplannedanddesignedfortheapplicationwhere
high level of safety is required, so the guarantee of the protection of
human life is impossible. Accordingly, do not use it in any of the following
applications.
1) Medical equipment used to maintain, control or otherwise affect human
life or physical health.
2) Mechanisms and machinery designed for the purpose of moving or
transporting people (For vehicle, railway facility or air navigation facility)
3) Important safety parts of machinery (Safety device, etc.)
●Donotuseitinanyofthefollowingenvironments.
1) Locationwherethereisanyammablegas,ammableobjector
explosive
2) Place with potential exposure to radiation
3) Location with the ambient temperature or relative humidity exceeding the
specicationrange
4) Location where radiant heat is added from direct sunlight or other large
heat source
5) Location where condensation occurs due to abrupt temperature changes
6) Location where there is any corrosive gas (sulfuric acid or hydrochloric
acid)
7) Locationexposedtosignicantamountofdust,saltorironpowder
8) Location subject to direct vibration or impact
●Donotusetheproductoutsidethespecications.Failuretodosomay
considerably shorten its life and cause a product breakdown or facility
operation stop.
2 Transportation ●Considerwellsothatitisnotbumpedagainstanythingordroppedduring
the transportation.
●Transportitusinganappropriatetransportationmeasure.
●Donotsteporsitonthepackage.
●Donotputanyheavythingthatcandeformthepackage,onit.
●Whenusingacranecapableof1tormoreofweight,haveanoperatorwho
hasqualicationsforcraneoperationandslingwork.
●Whenusingacraneorequivalentequipments,makesurenottohangaload
that weighs more than the equipment’s capability limit.
●Useahookthatissuitablefortheload.Considerthesafetyfactorofthe
hook in such factors as shear strength.
●Donotgetontheloadthatishungonacrane.
●Donotleavealoadhungupwithacrane.
●Donotstandundertheloadthatishungupwithacrane.

2
No. Operation
Description Precautions
3 Storage and
Preservation ●Thestorageandpreservationenvironmentconformstotheinstallation environment.
However, especially give consideration to the prevention of condensation.
4 Installation and
Start (1) Installation of Robot Main Body and Controller, etc. ●Makesuretosecurelyholdandxtheproduct(includingthework).Afall,
drop or abnormal motion of the product may cause damage or injury.
●Donotgetonorputanythingontheproduct.Failuretodosomaycause
an accidental fall, injury or damage to the product due to a drop of anything,
malfunction of the product, performance degradation, or shortening of its life.
●Whenusingtheproductinanyoftheplacesspeciedbelow,providea
sufcientshield.
1) Location where electric noise is generated
2) Locationwherehighelectricalormagneticeldispresent
3) Location with the mains or power lines passing nearby
4) Location where the product may come in contact with water, oil or
chemical droplets
(2) Cable Wiring
●Useourcompany’sgenuinecablesforconnectingbetweentheactuatorand
controller, and for the teaching tool.
●Donotscratchthecable.Donotbenditforcibly.Donotpullit.Donotcoilit
around. Do not insert it. Do not put any heavy thing on it.
Failuretodosomaycauseare,electricshockormalfunctiondueto
leakage or continuity error.
●Performthewiringfortheproduct,afterturningOFFthepowertotheunit,
so that there is no wiring error.
●Whenthedirectcurrentpower(+24V) is connected, take the great care of
the directions of positive and negative poles. If the connection direction is
notcorrect,itmightcauseare,productbreakdownormalfunction.
●Connectthecableconnectorsecurelysothatthereisnodisconnectionor
looseness.Failuretodosomaycauseare,electricshockormalfunctionof
the product.
●Nevercutand/orreconnectthecablessuppliedwiththeproductforthe
purpose of extending or shortening the cable length. Failure to do so may
causetheproducttomalfunctionorcausere.
(3) Grounding
●MakesuretoperformthegroundingoftypeD(FormerType3)forthe
controller. The grounding operation should be performed to prevent an
electric shock or electrostatic charge, enhance the noise-resistance ability
and control the unnecessary electromagnetic radiation.

3
No. Operation
Description Precautions
4 Installation and
Start (4) Safety Measures ●Whentheproductisunderoperationorinthereadymode,takethesafety
measures (such as the installation of safety and protection fence) so that
nobody can enter the area within the robot’s movable range. When the robot
under operation is touched, it may result in death or serious injury.
●Makesuretoinstalltheemergencystopcircuitsothattheunitcanbe
stopped immediately in an emergency during the unit operation.
●Takethesafetymeasurenottostartuptheunitonlywiththepowerturning
ON. Failure to do so may start up the machine suddenly and cause an injury
or damage to the product.
●Takethesafetymeasurenottostartupthemachineonlywiththeemergency
stop cancellation or recovery after the power failure. Failure to do so may
result in an electric shock or injury due to unexpected power input.
●Whentheinstallationoradjustmentoperationistobeperformed,giveclear
warnings such as “Under Operation; Do not turn ON the power!” etc. Sudden
power input may cause an electric shock or injury.
●Takethemeasuresothattheworkisnotdroppedinpowerfailureor
emergency stop.
●Wearprotectiongloves,goggleorsafetyshoes,asnecessary,tosecure
safety.
●Donotinsertangerorobjectintheopeningsintheproduct.Failuretodo
somaycauseaninjury,electricshock,damagetotheproductorre.
●Whenreleasingthebrakeonaverticallyorientedactuator,exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
5 Teaching ●Performtheteachingoperationfromoutsidethesafetyprotectionfence,if
possible. In the case that the operation is to be performed unavoidably inside
the safety protection fence, prepare the “Stipulations for the Operation” and
make sure that all the workers acknowledge and understand them well.
●Whentheoperationistobeperformedinsidethesafetyprotectionfence,the
worker should have an emergency stop switch at hand with him so that the
unit can be stopped any time in an emergency.
●Whentheoperationistobeperformedinsidethesafetyprotectionfence,
in addition to the workers, arrange a watchman so that the machine can be
stopped any time in an emergency. Also, keep watch on the operation so
that any third person can not operate the switches carelessly.
●Placeasign“UnderOperation”atthepositioneasytosee.
●Whenreleasingthebrakeonaverticallyorientedactuator,exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.

4
No. Operation
Description Precautions
6 Trial Operation ●Aftertheteachingorprogrammingoperation,performthecheckoperation
one step by one step and then shift to the automatic operation.
●Whenthecheckoperationistobeperformedinsidethesafetyprotection
fence,performthecheckoperationusingthepreviouslyspeciedwork
procedure like the teaching operation.
●Makesuretoperformtheprogrammedoperationcheckatthesafetyspeed.
Failure to do so may result in an accident due to unexpected motion caused
by a program error, etc.
●Donottouchtheterminalblockoranyofthevarioussettingswitchesin
the power ON mode. Failure to do so may result in an electric shock or
malfunction.
7 Automatic
Operation ●Beforetheautomaticoperationisstartedup,makesurethatthereisnobody inside the safety protection fence.
●Beforetheautomaticoperationisstartedup,makesurethatalltherelated
peripheral machines are ready for the automatic operation and there is no
error indication.
●Makesuretoperformthestartupoperationfortheautomaticoperation,out
of the safety protection fence.
●Inthecasethatthereisanyabnormalheating,smoke,offensivesmell,or
abnormal noise in the product, immediately stop the machine and turn OFF
thepowerswitch.Failuretodosomayresultinareordamagetothe
product.
●Whenapowerfailureoccurs,turnOFFthepowerswitch.Failuretodoso
may cause an injury or damage to the product, due to a sudden motion of
the product in the recovery operation from the power failure.
8 Maintenance and
Inspection ●Performtheworkoutofthesafetyprotectionfence,ifpossible.Inthecase that the operation is to be performed unavoidably inside the safety protection
fence, prepare the “Stipulations for the Operation” and make sure that all the
workers acknowledge and understand them well.
●Whentheworkistobeperformedinsidethesafetyprotectionfence,turn
OFF the power switch.
●Whentheoperationistobeperformedinsidethesafetyprotectionfence,the
worker should have an emergency stop switch at hand with him so that the
unit can be stopped any time in an emergency.
●Whentheoperationistobeperformedinsidethesafetyprotectionfence,
in addition to the workers, arrange a watchman so that the machine can be
stopped any time in an emergency. Also, keep watch on the operation so
that any third person can not operate the switches carelessly.
●Placeasign“UnderOperation”atthepositioneasytosee.
●Forthegreasefortheguideorballscrew,useappropriategreaseaccording
to the Instruction Manual for each model.
●Donotperformthedielectricstrengthtest.Failuretodosomayresultina
damage to the product.
●Whenreleasingthebrakeonaverticallyorientedactuator,exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
* Safety Protection Fence :In the case that there is no safety protection
fence, the movable range should be indicated.

5
No. Operation
Description Precautions
9Modication ●Donotmodify,disassemble,assembleoruseofmaintenancepartsnot
speciedbasedatyourowndiscretion.
●Insuchcase,thewarrantyisnotapplied.
10 Disposal ●Whentheproductbecomesnolongerusableornecessary,disposeofit
properly as an industrial waste.
●Donotputtheproductinarewhendisposingofit.
The product may burst or generate toxic gases.

6
Alert Indication
The safety precautions are divided into “Danger”-“Warning”-“Caution”-“Notice” according to the warning
level, as follows, and described in the Instruction Manual for each model.
Level Degree of Danger and Damage Symbol
Danger This indicates an imminently hazardous situation which, if the product
is not handled correctly, will result in death or serious injury. Danger
Warning This indicates a potentially hazardous situation which, if the product is
not handled correctly, could result in death or serious injury. Warning
Caution This indicates a potentially hazardous situation which, if the product is
not handled correctly, may result in minor injury or property damage. Caution
Notice This indicates lower possibility for the injury, but should be kept to use
this product properly. Notice

7
Precautions in Handling
PS-24 Power Supply is a power supply unit dedicated for IAI controllers which utilizes 24V
DC as a power source.
 Thereare2types,100VACand200VACspecications,fortheinputpower.
Even when lack of the power capacity is occurred, this power supply does not need to be
replaced with another power supply with a bigger capacity. Another unit of this product
can be added to the connection to perform a parallel operation. 5 units maximum can be
connected.
 Thispowersupplyunitisdesignedtoacceptsomevoltageuctuation(24V±10%)sothatthe
unit can be used in a parallel operation. (24V±10%)
This power supply cannot be connected together with products not made by IAI.
Make sure that the connection to the I/O terminals is correctly established as shown in this
Instruction Manual.
When wiping off the dirt on the product, use a neutral detergent. Do not use alcohol
otherwise it may damage the paint and silk print on the surface.

8

9
1. Name and Function of Each Part
1. Name and Function of Each Part
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
1) RDY display
It is illuminated in normal operation.
[Refer to "2. RDY Display and RDY Output Signal".]
2) Variable dial to set over load detection level
For manufacturer’s use only. Do not remove the seal.
3) RDY output signal
It turns ON (electrically conducted) in normal operation.
[Refer to "2. RDY Display and RDY Output Signal".]
4) 5) +24V output terminal
* 4) and 5) are connected internally.
6) 7) 0V output terminal
* 6) and 7) are connected internally.
8) Frame ground terminal
It is the ground terminal that is connected to the power supply main housing.
9) AC input terminal
Input terminal common for 100V AC and 200V AC types.

10
1. Name and Function of Each Part
10) AC input terminal (for 100V AC)
Input terminal for 100V AC type.
Note:Donotconnecttheunittoapowersourcethatisnotspecied.
11) AC input terminal (for 200V AC)
Input terminal for 200V AC type.
Note:Donotconnecttheunittoapowersourcethatisnotspecied.
(Note) Connect the power supply as follows;
for100VACinputspecication,9)and10),and
for200VACinputspecication,9)and11).
Theycannotbeusedincommonforeachspecication.

11
2. RDY Display and RDY Output Signal
2. RDY Display and RDY Output Signal
In a normal operation, RDY display should be illuminated and RDY output signal should be
turned ON (electrically conducted). In case this RDY display is not illuminated and RDY output
signal is turned OFF, lower the load or add another unit of this power supply.
Take note that there are also other considerable causes that the RDY display light and RDY
output signal are OFF as listed below.
Output is stopped due to the effect of the over temperature protection circuit, over voltage
protection circuit, etc.
Input power is OFF or low
Also, there will be a failure in normal operation when the over current protection is working.
RDY display and RDY output signal are linked to each other.
Power Status RDY Output Signal RDY Display
In normal operation
(Whentheloadisunderthespeciedvalue) ON Illuminating
Duty ratio exceeds the setting value
Output is stopped
Power is not input or low
(Over current detection circuit is working)
OFF OFF
Pleasemakesurethepowersupplycabletousesatisesthefollowingspecications:
Item Specication
Applicable wire
Twisted wire: AWG size 22 (0.3 mm2) (copper wire)
(Note) Pay attention to terminal treatment to avoid a short
circuit resulting from chips. If the wire path is long,
install a relay terminal block and change the wire size.
Input
Terminal
Relay
Terminal Block
Power Supply
Terminal Block
AWG18
(0.75mm2)AWG22
(0.3mm2)
Insulating sheath temperature
rating 60°C or more
Stripped wire length 9mm
RDY output signal is insulated with a photocoupler and is an open collector output.
47Ω
(C)
(E)
VceMAX =30V
IcMAX =20mA
Residual voltage: approx. 1.6V (at Ic =20mA)
(Note) If connecting this terminal in series, consider the residual voltage.

12
3. Product Check
3. Product Check
Thisproductiscomprisedofthefollowingpartsifitisofstandardconguration.
Ifyoundanyfaultinthecontainedmodeloranymissingparts,contactusorourdistributor.
3.1 Parts (The option is excluded.)
No. Part Name Model
1 24V Power Supply Main Unit Refer to “How to read the model plate”, “How
to read the model No.”
Accessories
2 First Step Guide
3 Instruction Manual (DVD)
4 Safety Guide
3.2 Instruction Manuals related to this product, which are contained in
the instruction manual (DVD)
No. Name Manual No.
1 PS241/PS242 24V Power Supply Instruction Manual ME0129
3.3 How to read the model plate
3.4 How to read the model No.
PS-241
[Input Power]
1 : 100V AC
2 : 200V AC
PS241
800061910 A1
Model
Serial number

13
4. Basic Specications
4. BasicSpecications
Specications
SpecicationItem 100VACSpecication
PS241 200VACSpecication PS242
Rated Voltage DC Output 24V±10%(uctuatesdependingonduty)
Rated DC Current Output 8.5A
Peak DC Current Output 17A
Rated Output Wattage 204W
Efciency 80%
Rated Input Voltage
(frequency) 100 to 115V AC (50/60Hz) 200 to 230V AC (50/60Hz)
Input Voltage Range 90 to 125V AC 180 to 250V AC
Input Current 3.5A
(when total duty of 100V AC
is applied)
1.8A
(when total duty of 200V AC
is applied)
Output Holding Time 20 [msec] (Condition; ambient temp. 25°C, rated input and
output)
Protection Circuit Over current protection, over voltage protection,
over temperature protection, over load protection
Parallel Operation Applicable
Operation Ambient Temp. 0 to 50°C (with derating*1)
Operation Ambient
Humidity 30to85%RH(non-condensing)
Cooling Method Natural air-cooling
Voltage Durability Output – input … 2000V AC 1min.
Input – housing …2000V AC 1min.
Insulation Strength Output – housing … 100MWmin. at 500V DC
Circuit System Line-commutatedybackconverter
Mass Approx. 0.9kg
*1 Derating: it is a method to use a device with a load lower than the rated value for the purpose to
decrease a risk of malfunction.

14
5. External Dimensions
5. External Dimensions
64.5
31.5 33
31.5 33
148±0.5
158
5
10138
φ5 (For installation)
R2.5 (For installation)
10
+24V
+24V
0V
0V
FG
AC(N)
AC100(L)
AC200(L)
5
5
16
139.5
13
10 8
M3.5
Terminal screw

15
6. Installation Environment
6. Installation Environment
Do not use this product in the following environment.
Location where the surrounding air temperature exceeds the range of 0 to 50°C
Location where condensation occurs due to abrupt temperature changes
 Relativehumiditylessthan30%RHorgreaterthan85%RH
Location exposed to corrosive gases or combustible gases
 Locationexposedtosignicantamountofdust,saltorironpowder
Location subject to direct vibration or impact
Location exposed to direct sunlight
Location where the product may come in contact with water, oil or chemical droplets
Whenusingtheproductinanyofthelocationsspeciedbelow,provideasufcientshield.
Location subject to electrostatic noise
 Locationwherehighelectricalormagneticeldispresent
Location with the mains or power lines passing nearby

16
7. Installation and Noise Elimination
7. Installation and Noise Elimination
1. Grounding
Power
Supply
Power
Supply
Other
equipment
Other
equipment Other equipment
Do not share the ground wire with or connect
to other equipment. Ground each controller.
+24V
+24V
0V
0V
FG
AC(N)
AC100(L)
AC200(L)
Class D grounding
(Formerly Class- III grounding:
Grounding resistance at 100Ωor less)
2. Heatsink and Mounting Method
This is a natural air-cooling type power supply. Mount the unit on a wall to make it vertical as
shown in the picture below.
100mm or more
20mm
or more
50mm
or more
50mm
or more
20mm
or more