Iai ERC FORTH EDITION User Manual
ERC Actuator with
Integrated Controller
Operation Manual Forth Edition
CAUTION
2. Basic Parameter Settings
When the power is input for the first time, at least the two parameters specified below must be set in
accordance with the intended application.
If these parameters are not set properly, the ERC will not function correctly. So, pay due attention to
ensure the parameters are set properly.
For details on the setting method, refer to the “parameter settings” of the PC or teaching pendant.
[1] PIO pattern selection
This controller provides three PIO (parallel I/O) patterns to support various applications.
To select a desired PIO pattern, set a number between “0” and “2” in parameter No. 25 (PIO pattern
selection).
The factory setting is “0.”
Setting of parameter
No. 25
0
1
2
[2] Enabling/Disabling the Pause Signal (*STP)
The pause signal uses the contact B logic to provide a failsafe function.
Therefore, this signal must remain ON in normal conditions of use.
Since there are applications where this signal is not used, a parameter is provided to disable the
pause signal so it doesn’t have to be turned ON.
To select a desired setting, set “0” or “1” in user parameter No. 15 (Pause input disable selection).
Enable (use) the signal 0
Disable (do not use) the signal 1
The factory setting for this parameter is “0: [Enable].”
8 points
The basic pattern providing eight positioning points.
3 points (air cylinder)
Use of the ERC as an air cylinder is assumed in this pattern.
The number of positioning points is limited to three, but a direct
command input and a position complete output are provided for each
target position in line with the conventional practice of air cylinder
control.
This lets the user control the ERC just like an air cylinder.
16 points
The number of positioning points is increased to 16.
However, the home return input is not provided.
Setting
Feature of the PIO pattern
CAUTION
3. Recommendation for Backing up Latest Data
The controller part of this actuator uses nonvolatile memory to store the position table and
parameters. Normally the memory will retain the stored data even after the power is disconnected.
However, the data may be lost if the nonvolatile memory becomes faulty.
(We strongly recommend that the latest position table and parameter data be backed up so that the
data can be restored quickly in the event of power failure, or when the controller must be replaced for
a given reason.)
The data can be backed up using the following methods:
[1] Save to a CD or FD from the PC software.
[2] Hand write the position table and parameter table on paper.
4. Compatibility of Teaching Pendant
The existing teaching pendants of <RCA-T> and <RCA-E> types can be used with the ERC
controller, but your RCA-T/RCA-E teaching pendant will require some modification.
If you are using a teaching pendant of either type, please send it to IAI. We will perform the
necessary modification and return it to you as soon as possible.
Teaching pendants that have already been modified have a specific code at the end of their serial
number. Please check the serial number of your teaching pendant to see if it requires modification.
Teaching pendant model Code at the end of serial number
RCA-T
RCA-E
RCA-P
RCB-J
• • • • • • • F3
• • • • • • • H3
• • • • • • • H3
• • • • • • • B2
CAUTION
1. When Using Multiple 24-V Power Supplies
If multiple 24-V power supplies are used, be sure to adjust 0 V to the same level on
all units. If 0 V varies among the power supplies, the controller board, SIO converter
or other hardware may be damaged.
[Connection example]
24-V power supply
[1]
24-V power supply
[2]
24-V power supply
[3]
24-V power supply
[4]
24-V power supply
[5]
24V
0V
24V
0V
24V
0V
24V
0V
24V
0V
SIO
converter
PLC
communication
module
Actuator 1
Actuator 2
Actuator 3
Actuator 4
Safety Precautions
Before using the ERC actuator, please read the information provided in this chapter to ensure the correct
use of the actuator.
The precautions described below are designed to help you use the product safely and avoid bodily injury
and/or property damage.
Directions are classified as “danger,” “warning,” “caution” and “note,” according to the degree of
risk.
Danger
Failure to observe the instruction will result in an imminent danger leading to
death or serious injury.
Warning
Caution
Note
Failure to observe the instruction may result in death or serious injury.
Failure to observe the instruction may result in injury or property damage.
The user should take heed of this information to ensure the proper use of the
product, although failure to do so will not result in injury.
This product has been designed and manufactured as a component for use in general industrial
machinery.
Devices must be selected and handled by a system designer, personnel in charge of the actual operation
using the product or similar individual with sufficient knowledge and experience, who has read both the
catalog and operation manual (particularly the “Safety Precautions” section). Mishandling of the product
poses a risk.
Please read the operation manuals for all devices, including the main unit and controller.
It is the user’s responsibility to verify and determine the compatibility of this product with the user’s
system, and to use them properly.
After reading the catalog, operation manual and other materials, be sure to keep them in a convenient
place easily accessible to the personnel using this product.
When transferring or loaning this product to a third party, be sure to attach the catalog, operation manual
and other materials in a conspicuous location on the product, so that the new owner or user can
understand its safe and proper use.
The danger, warning and caution directions in this “Safety Precautions” do not cover every possible case.
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
General
z Do not use this product for 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
3. Important safety parts of machinery
This product has not been planned or designed for applications requiring high levels of safety. Use of
this product in such applications may jeopardize the safety of human life. The warranty covers only the
product as it is delivered.
Installation
z Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The product
may ignite, burn or explode.
z When installing the product, be sure to provide reliable means for securing/affixing the product (including the
load) in place. If the product tips, drops or malfunctions, injury may result.
z Avoid using the product in a place where it may come in contact with water or oil droplets.
z Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening
the cable length. Doing so may result in fire.
Operation
z Do not enter the operating range of the machine when the machine is operating or is able to operate. Injury
may result due to a sudden movement to the actuator.
z Do not pour water onto the product. Spraying water over the product, washing it with water or using it in water
may cause the product to malfunction, resulting in injury, electric shock, fire, etc.
Maintenance, Inspection, Repair
z Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in
injury, electric shock, fire, etc.
z Do not disassemble and reassemble the components relating to the basic structure of the product or its
performance and function. Doing so may result in injury, electric shock, fire, etc.
Warning
General
z Do not use the product outside the specifications. Using the product outside the specifications may cause it
to fail, stop functioning or sustain damage. It may also significantly reduce the service life of the product. In
particular, observe the maximum loading capacity and speed.
Installation
z If the machine will stop in the case of system problem such as emergency stop or power failure, design a
safety circuit or other device that will prevent equipment damage or injury.
z Be sure to provide Class D grounding for the actuator (formerly Class 3 grounding: Grounding resistance at
100 Ω or less). Leakage current may cause electric shock or malfunction.
z Before supplying power to and operating the product, always check the operation area of the equipment to
ensure safety. Supplying power to the product carelessly may cause electric shock or injury due to contact
with the moving parts.
z Wire the product correctly by referring to the operation manual. Securely connect the cables and connectors
so that they will not be disconnected or come loose. Failure to do so may cause the product to malfunction or
cause fire.
Operation
z Do not touch the terminal block or various switches while the power is supplied to the product. Failure to
observe this instruction may result in electric shock or malfunction.
z Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.),
confirm that the servo is turned off (using the teaching pendant). Failure to observe this instruction may result
in injury.
z The cables supplied with the product are flexible, but they are not robot cables. Do not store the cables in a
movable cable duct (cable bearer, etc.) that bends more than the specified bending radius.
z Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object or
pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock, malfunction,
etc.
z Turn off the power to the product in the event of power failure. Failure to do so may cause the product to
suddenly start moving when the power is restored, thus resulting in injury or product damage.
z If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing to use
the product may result in product damage or fire.
z If the product begins producing noise or vibration has suddenly increased, immediately stop its operation.
Continuing to use the product in such condition may cause a product breakdown or damage, resulting in
malfunction, runaway, and so on.
z If any of the internal protective devices (alarms) of the product has actuated, turn off the power immediately.
Continuing to use the product may result in product damage or injury due to malfunction. Once the power
supply is cut off, investigate and remove the cause and then turn on the power again.
z If the LEDs on the product do not illuminate after turning on the power, turn off the power immediately.
z Do not climb onto the product or stand or place any object on top. You may slip and injure yourself, and a
tipping product or dropping object may also cause injury. Or, a product breakdown or damage may occur,
resulting in malfunction, runaway, and so on.
Maintenance, Inspection, Repair
z Before conducting maintenance/inspection, parts replacement or other operations on the product, completely
shut down the power supply. At this time, take the following measures:
1. Display a sign that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER” at a conspicuous place,
in order to prevent a person other than the operator from accidentally turning on the power.
2. When two or more operators are to perform maintenance/inspection together, always call out every time
the power is turned on/off or an axis is moved in order to ensure safety.
Disposal
z Do not throw the product into fire. The product may burst or generate toxic gases.
Caution
Installation
z Do not use the product in a place exposed to direct sunlight (UV ray), salt, high humidity or atmosphere
containing organic solvent or phosphate-ester machine oil. The product may lose its function over a short
period of time, or exhibit a sudden drop in performance or its service life may be significantly reduced. The
product may also malfunction if used in these environments.
z Do not use the product in an atmosphere of corrosive gases (sulfuric acid or hydrochloric acid), etc. Rust may
form and reduce the structural strength.
z When using the product in any of the places specified below, provide a sufficient shield. Failure to do so may
result in malfunction:
1. Place where large current or high magnetic field is present
2. Place where welding or other operations are performed that cause arc discharge
3. Place subject to electrostatic noise
4. Place with potential exposure to radiation
z Install the product in a place not subject to significant dust and free from iron powder. Installing the product in
such a place may cause malfunction.
z Do not install the product in a place subject to large vibration or impact (4.9 m/s
result in the malfunctioning of the product.
z Provide an emergency-stop device in a readily accessible position so the device can be actuated immediately
upon occurrence of a dangerous situation during operation. Lack of such device in an appropriate position
may result in injury.
z Provide sufficient maintenance space when installing the product. Routine inspection and maintenance
cannot be performed without sufficient space, and an equipment stoppage, product breakdown or injury may
result.
z When transporting or installing the product, exercise due caution to prevent injury by securely supporting the
product using a lift or other supporting equipment, engaging multiple persons to work together, and so on.
z Do not hold the moving parts of the product or its cables during installation. It may result in injury.
z Use IAI’s genuine products for the component units such as the actuator, relay cables and teaching pendant.
z The brake mechanism of the product is designed to prevent the slider from dropping in a vertical application
when the power is turned off. Do not use it as a safety brake (means for reducing the speed) or for any other
purpose.
z Before installing or adjusting the product or performing other operations on the product, display a sign that
reads, “WORK IN PROGRESS. DO NOT TURN ON POWER.” If the power is turned on inadvertently, injury
may result due to electric shock or sudden activation of an actuator.
2
or more). Doing so may
Operation
z Turn on the power to individual equipment one by one, starting from the equipment at the highest level in the
system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or product
damage.
z Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.
Maintenance, Inspection, Repair
z Wear protective goggles when applying grease to the actuator. If splashed grease enters the eyes, eye
inflammation may result.
z When the power is turned off and a cover is opened to replace the battery, etc., do not touch the capacitor
connection terminal of the product immediately after the power is turned off (within 30 seconds). Residual
voltage may cause electric shock.
z Do not touch the terminals when performing an insulation resistance test. Electric shock may result. (Do not
perform any withstand voltage test with the product that uses DC voltage.)
Note
General
z If you are planning to use the product under a condition or environment not specified in the catalogs and
operation manual, or in an application requiring strict safety such as aircraft facility, combustion system,
entertainment machine, clean-room environment, safety device or other equipment having significant impact
on human life or property, design operating ranges with sufficient margins from the ratings and design
specifications or provide sufficient safety measures such as fail-safes. Whatever you do, always consult IAI’s
sales representative.
Installation
z When the product is to be installed and used in a vertical position, be sure to use the dedicated specification
for vertical application (equipped with brake).
z Isolate the operating part of the mechanical equipment with a protective cover, etc., to prevent direct contact
by the operator or other personnel.
z Do not configure a control circuit that will cause the load to drop in case of power failure. Configure a control
circuit that will prevent the table or load from dropping when the power to the machine is cut off or an
emergency stop is actuated.
z Take note of the following items to increase the linearity of table operation and ensure smooth movement of
the ball screw and linear guides:
1. The mounting surface of the actuator must have a flatness of 0.05 mm or less.
2. Provide a sufficient installation surface to ensure rigidity of the actuator.
Installation, Operation, Maintenance
z When handling the product, wear protective gloves, protective goggles, safety shoes or other necessary gear
to ensure safety.
Maintenance, Inspection, Repair
z Use the specified ball screw grease for maintenance. In particular, be careful not to mix fluorine grease with
lithium grease, because it may damage the mechanism due to poor lubrication, increased resistance, and so
on.
Disposal
z When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste.
Others
IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the items specified
in “Safety Precautions.”
If you have any question regarding the product, please contact your nearest IAI sales office. The addresses
and phone numbers of our sales offices are provided at the end of this operation manual.
Prohibited Handling of Cables
When designing an application system using this actuator, incorrect wiring or connection of each cable
may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway
system. This section explains prohibited handling of cables. Read the information carefully to connect the
cables properly.
Ten Rules for Handling Cables (Must be Observed!)
1. Do not let the cable flex at a single point.
2. Do not let the cable bend, kink or twist.
Steel band
(piano wire)
3. Do not pull the cable with a strong force.
Bundle loosely.
4. Do not let the cable receive a turning force at a
single point.
6.
Do not pinch, drop a heavy object onto or cut
the cable.
Use a curly
cable.
5. When fixing the cable, provide a moderate slack
and do not tension it too tight.
Do not use a spiral tube where
the cable flexes frequently.
A
7. Do not let the cable get tangled or kinked in a cable bearer or flexible tube. When bundling the cable,
keep a certain degree of flexibility (so that the cable will not become too taut when bent).
8. Do not cause the cables to occupy more than 60% of the space in the cable bearer.
Do not place the connector in the cable bearer.
Cable
Cable bearer
9. Always use a robot cable if the cable is likely to flex significantly.
[Standard structure of cable]
The standard structure of
cable will vary depending on
the manufacturer and type of
cable.
Ì Need for Robot Cables
A cable connected to a moving part of an actuator system will inevitably receive repeated bending loads at
the base of the cable. As a result, the cores in the cable may break over time. To minimize the risk of
cable breakage, we strongly recommend that a robot cable
in this type of application.
Cover
Shield
Protective layer
offering significantly higher flexibility be used
Signal line (copper + tin)
bsorbing material (When the
cable is bent, this material is
crushed by the surrounding signal
lines to maintain the shape of the
signal lines.)
Before Use
Caution
1. Be sure to read this operation manual to ensure the proper use of this product.
2. Unauthorized use or reproduction of a part or all of this operation manual is prohibited.
3. IAI shall not be liable whatsoever for any loss or damage arising from a handling or operation not
specified in this operation manual.
4. The information contained in this operation manual is subject to change without notice.
Action to Be Taken in Case of Emergency
* If this product is found to be in a dangerous condition, immediately turn off all power switches of the main unit
and connected equipment or immediately disconnect all power cables from the outlets. (“Dangerous
condition” refers to a situation where the product is generating abnormal heat or smoke or has ignited and a
fire or danger to human health is anticipated.)
Table of Contents
1. Overview ................................................................................................. 1
1.1 Introduction ....................................................................................................................................... 1
1.2 Meaning of the Model Name ............................................................................................................ 2
1.3 Specifications.................................................................................................................................... 3
1.3.1 Correlation Diagrams of Speed and Load Capacity – Slider Type ........................................ 4
1.3.2 Correlation Diagrams of Speed and Load Capacity – Rod Type ........................................... 5
1.4 Safety Precautions............................................................................................................................ 7
1.5 Warranty Period and Scope of Warranty .......................................................................................... 8
1.6 Transportation and Handling ............................................................................................................ 9
1.6.1 Handling before Unpacking.................................................................................................... 9
1.6.2 Handling after Unpacking....................................................................................................... 9
1.7 Installation Environment and Noise Elimination ............................................................................. 10
1.7.1 Installation Environment....................................................................................................... 10
1.7.2 Storage Environment ........................................................................................................... 10
1.7.3 Power Supply........................................................................................................................11
1.7.4 Noise Elimination ..................................................................................................................11
1.8 Cabling............................................................................................................................................ 13
2. Installation ............................................................................................. 14
2.1 Name of Each Part ......................................................................................................................... 14
2.1.1 Slider Type (SA6/SA7)......................................................................................................... 14
2.1.2 Rod Type (RA54/RA64) ....................................................................................................... 14
2.1.3 (1) Rod Type with a Single Guide (RA54GS/RA64GS) ....................................................... 15
(2) Rod Type with Double Guides (RA54GD/RA64GD) ...................................................... 15
2.2 Installation....................................................................................................................................... 16
2.2.1 Slider Type ........................................................................................................................... 16
z Installing the actuator.............................................................................................................. 16
2.2.2 Rod Type.............................................................................................................................. 17
z Affixing with a flange ............................................................................................................... 17
z Affixing through holes in a flange............................................................................................ 17
z Affixing with foot brackets (optional) ....................................................................................... 18
2.2.3 Installing the Load................................................................................................................ 20
z Slider Type .............................................................................................................................. 20
z Rod Type................................................................................................................................. 21
z Rod type with a guide(s) ......................................................................................................... 21
3. Wiring.................................................................................................... 22
3.1 Basic Structure................................................................................................................................ 22
3.2 I/O Connections for PIO Pattern 1 [3 Points] (Air Cylinder)............................................................ 25
3.2.1 Explanation of I/O Signals.................................................................................................... 25
3.2.2 Details of Input Signals ........................................................................................................26
Movement to each position (ST0 to ST2) ............................................................................... 26
Pause (*STP) .......................................................................................................................... 26
3.2.3 Details of Output Signals ..................................................................................................... 27
Completion of each position (PE0 to PE2) ............................................................................. 27
Alarm (*ALM)........................................................................................................................... 27
3.3
I/O Connections for PIO Pattern 0 [8 Points].................................................................................. 28
3.4 I/O Connections for PIO Pattern 2 [16 Points]................................................................................ 28
3.4.1 Explanation of I/O Signals.................................................................................................... 29
3.4.2 Details of Input Signals ........................................................................................................29
Start (CSTR)............................................................................................................................ 29
Command position number (PC1 to PC8) .............................................................................. 30
Pause (*STP) .......................................................................................................................... 30
Home return (HOME)..............................................................................................................30
3.4.3 Details of Output Signals ..................................................................................................... 30
Position complete (PEND) ...................................................................................................... 30
Home return completion (HEND) ............................................................................................ 31
Zone (ZONE)........................................................................................................................... 31
Alarm (*ALM)........................................................................................................................... 31
3.5 Configuration Using a SIO Converter .............................................................................................32
3.6 Configuration Using an Insulated PIO Terminal Block.................................................................... 36
3.7 Configuration Using Both SIO Converter and Insulated PIO Terminal Block................................. 40
3.8 Controlling Multiple Axes via Serial Communication ...................................................................... 43
3.8.1 Basic Specifications ............................................................................................................. 43
3.8.2 Address Assignment ............................................................................................................ 43
3.8.3 Wiring Examples for Linking Multiple Axes .......................................................................... 44
z Using only a SIO converter ..................................................................................................... 44
z Using both SIO converter and insulated PIO terminal block .................................................. 45
3.9
Emergency-Stop Circuit.................................................................................................................. 46
3.10 Relay Cable.................................................................................................................................... 48
4. Electrical Specifications......................................................................... 50
4.1 Controller ........................................................................................................................................ 50
4.2 I/O Signal Interface Circuit.............................................................................................................. 51
4.2.1 External Input Specifications................................................................................................ 51
4.2.2 External Output Specifications............................................................................................. 52
4.3 SIO Converter (Optional)................................................................................................................ 53
4.4 Insulated PIO Terminal Block (Optional).........................................................................................55
5. Data Entry <Basics>.............................................................................. 61
5.1 Description of Position-Data Table.................................................................................................. 62
5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value .................................. 64
5.2 Explanation of Modes ..................................................................................................................... 66
5.2.1 Positioning Mode ................................................................................................................. 66
5.2.2 Push & Hold Mode ............................................................................................................... 66
5.2.3 Speed Change during Movement ........................................................................................ 68
5.2.4 Operation at Different Acceleration and Deceleration Settings ........................................... 68
5.2.5
Pause ................................................................................................................................... 69
5.2.6 Zone Signal Output ..............................................................................................................69
5.2.7 Home Return........................................................................................................................ 69
6. Operation in the “3 Points (Air Cylinder)” Mode <Practical Operation>. 70
6.1 Overview of the “3 Points” Mode .................................................................................................... 70
6.2 How to Start .................................................................................................................................... 72
6.3 Moving Operation ........................................................................................................................... 74
7. Operation in the “8 Points” and “16 Points” Modes
<Practical Operation> ........................................................................... 78
7.1 How to Start .................................................................................................................................... 78
7.2 How to Execute Home Return ........................................................................................................ 80
7.2.1 8 Points ................................................................................................................................ 80
7.2.2 16 Points .............................................................................................................................. 81
7.3 Home Return and Movement after Start (16 Points) ...................................................................... 82
7.4 Positioning Mode (Back and Forth Movement between Two Points) ............................................. 84
7.5 Push & Hold Mode.......................................................................................................................... 86
7.5.1 Return Action after Push & Hold by Relative Coordinate Specification ............................... 87
7.6 Speed Change during Movement................................................................................................... 88
7.7 Operation at Different Acceleration and Deceleration Settings ...................................................... 90
7.8 Pause.............................................................................................................................................. 92
7.9 Zone Signal Output......................................................................................................................... 94
7.10 Incremental Moves......................................................................................................................... 96
7.11 Notes on Incremental Mode........................................................................................................... 98
8. Parameters.......................................................................................... 100
8.1 Parameter Classification............................................................................................................... 100
8.2 Parameter Table ........................................................................................................................... 100
8.3 Parameter Settings ....................................................................................................................... 101
8.3.1 Parameters Relating to the Actuator Stroke Range........................................................... 101
z Soft limit ................................................................................................................................ 101
z Zone boundary ...................................................................................................................... 101
z Home return direction ........................................................................................................... 102
z Home return offset ................................................................................................................ 102
8.3.2 Parameters Relating to the Actuator Operating Characteristics........................................ 102
z Default speed ........................................................................................................................ 102
z Default acceleration/deceleration.......................................................................................... 102
z Default positioning band (in-position) ................................................................................... 102
z Default acceleration only MAX flag ....................................................................................... 103
z Push & hold stop judgment period ........................................................................................ 103
z Current-limiting value at standstill during positioning............................................................ 103
z Current-limiting value during home return ............................................................................ 104
8.3.3 Parameters Relating to the External Interface................................................................... 104
z PIO pattern selection ............................................................................................................ 104
z Movement command type..................................................................................................... 104
z Pause input disable selection ............................................................................................... 105
z Serial communication speed................................................................................................. 105
z Minimum delay time for slave transmitter activation ............................................................. 105
8.3.4 Servo Gain Adjustment ...................................................................................................... 106
z Servo gain number................................................................................................................ 106
9. Troubleshooting................................................................................... 107
9.1 Action to Be Taken upon Occurrence of Problem......................................................................... 107
9.2 Alarm Level Classification ............................................................................................................ 107
9.3 Alarm Description and Cause/Action............................................................................................ 108
(1) Message level alarms ........................................................................................................... 108
(2) Operation-cancellation level alarms...................................................................................... 109
(3) Cold-start level alarms ...........................................................................................................110
9.4 Messages Displayed during Operation Using the Teaching Pendant or PC Software.................. 111
9.5 Specific Problems ..........................................................................................................................113
z I/O signals cannot be exchanged with the PLC. ....................................................................113
z The LED lamp does not illuminate after the power is input. ..................................................113
z The LED illuminates in red when the power is turned on. .....................................................113
z Home return ends in the middle in a vertical application. ......................................................113
z Noise occurs during downward movements in a vertical application. ...................................113
z Vibration occurs when the actuator is stopped. .....................................................................114
z The actuator overshoots when decelerated to a stop............................................................114
z The home and target positions sometimes shift on the rod-type actuator.............................114
z The speed is slow during push & hold operation. ..................................................................114
z The actuator operates abnormally when the servo is turned on following the power
on. ..........................................................................................................................................114
10. Maintenance and Inspection ............................................................... 115
10.1 Inspection Items and Timings .......................................................................................................115
10.2 Visual Inspection of Appearance...................................................................................................115
10.3 Cleaning ........................................................................................................................................115
10.4 Internal Check (Slider Type)..........................................................................................................116
10.5 Internal Cleaning (Slider Type) .....................................................................................................117
10.6 Greasing the Guide (Slider Type) .................................................................................................117
10.7 Greasing the Ball Screw (Slider Type)..........................................................................................119
10.8 Greasing the Rod Slide Surface .................................................................................................. 120
10.9 Motor Replacement Procedure .................................................................................................... 121
* Appendix ................................................................................................ 123
Example of Basic ERC Positioning Sequence....................................................................................... 123
Recording of Position-Data Table .......................................................................................................... 126
Parameter Records................................................................................................................................ 127
1. Overview
1.1 Introduction
Thank you for purchasing the Easy All-in-One Robo Cylinder (hereinafter referred to as “ERC”). This
manual explains the features and operating procedures of the product.
If not used or handled properly, even a brilliant product cannot fully demonstrate its function or may cause
an unexpected breakdown or end its life prematurely. Please read this manual carefully and handle the
product with utmost care while ensuring its correct operation. Keep this manual in a convenient place so
the relevant sections can be referenced readily when necessary.
If you are also using the optional PC software or teaching pendant, also refer to the operation manual for
the applicable item.
* We have made every effort to ensure accuracy of the information provided in this manual. Should you
find an error, however, or if you have any comment, please contact IAI.
Keep this manual in a convenient place so it can be referenced readily when necessary.
1
1.2 Meaning of the Model Name
<Series name>
<Type>
Slider type
Rod type
<Encoder type>
I: Incremental
<Motor type>
PM: Pulse motor
<Options>
Blank: No option
B: With brake
NM: Reversed-home specification
FT: Foot bracket (Specified only
for rod types.)
EN: CE-compliant NPN
specification
EP: CE-compliant PNP
specification
<Relay cable length>
Blank: No cable
Length specification (Example) X08 = 8 m
Robot cable specification
Connectors on both ends
<Stroke>
50 to 600 mm
(Standard lengths are multiples of 50 mm.)
(Example) 100 = 100 mm
Robot cable / Connectors on both
ends
<Ball screw lead>
2
1.3 Specifications
Model
Stroke (mm) and maximum speed (mm/sec) (Note 1)
Slider type
Rod type
(Note 1) The figures in blank bands indicate the maximum speeds for respective strokes. The maximum speeds
during vertical operation are shown in parentheses.
(Note 2) The load capacity is based on operation at the rated acceleration. In the case of a guide type, find the
applicable load capacity in the above table and subtract the weight of the guide to obtain the effective load
capacity.
Load capacity (Note 2)
Horizontal
Vertical
Rated acceleration
Horizontal
Vertical
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1.3.1 Correlation Diagrams of Speed and Load Capacity – Slider Type
High-speed type
Medium-speed type
Low-speed type
(Note) In the above graphs, the number after each type name indicates the lead.
Horizontal installation Vertical installation
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Load capacity (kg)
Load capacity (kg)
Speed (mm/sec)
Speed (mm/sec)
Speed (mm/sec)
4
1.3.2 Correlation Diagrams of Speed and Load Capacity – Rod Type
High-speed type
Medium-speed type
Low-speed type
(Note) In the above graphs, the number after each type name indicates the lead.
Horizontal installation Vertical installation
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Speed (mm/sec)
Load capacity (kg)
Load capacity (kg)
Speed (mm/sec)
Speed (mm/sec)
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Load Applied to the Actuator
(1) Slider type
• Keep the load applied to the slider below the value stated in the applicable specification item.
In particular, pay attention to the moment applied to the slider, allowable overhung length and load
capacity.
• If the slider is used in an overhung application with the load extending in the Y-axis direction, keep
moments Ma and Mc to one-half the rated moment or less to prevent the base from deforming.
(2) Rod type
• Keep the load applied to the rod below the value specified in the catalog.
• Make sure the center of the rod axis corresponds to the moving direction of the load.
• Application of lateral load may cause an actuator damage or breakdown.
• If the rod is to be subjected to lateral load, provide a guide or other support in
the moving direction of the load.
• Do not apply rotating torque to the rod (slide shaft).
* It will result in internal damages.
When tightening the nut at the tip of the rod, secure the rod using a
wrench of size 13 (RA54 type) or 17 (RA64 type).
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1.4 Safety Precautions
Read the following information carefully and provide safety measures with due consideration.
This product has been developed as a drive component for automated machinery and the like, and is
therefore designed not to generate excessive torque or speed beyond the levels needed to drive
automated equipment. However, the following instructions must be strictly observed to prevent an
unexpected accident.
1. Assume that the product cannot be handled or operated in any manner not specified in this manual,
and do not attempt any such handling or operation.
2. Do not enter the operating range of the machine while the machine is operating or is able to operate
(the controller power is ON). If the machine is used in a place accessible to other people, enclose its
operating range using a safety cage, etc.
3. Always turn off the power supply to the controller before assembling/adjusting or
maintaining/inspecting the machine. During assembly/adjustment or maintenance/inspection, put a
plate or other visible sign in a conspicuous place indicating that work is in progress. Provide sufficient
safety measures to prevent another person from inadvertently plugging in the cable during work.
4. If two or more persons work together, set signaling methods so each person can confirm the safety of
other(s) during work. Especially when the work requires an axis or axes to be moved—with or without
the power and by motor drive or manual operation—the person moving each axis should always call
out beforehand to ensure safety.
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1.5 Warranty Period and Scope of Warranty
The ERC you have purchased passed IAI’s shipping inspection implemented under the strictest
standards. The unit is covered by the following warranty:
1. Warranty Period
The warranty period shall be one of the following periods, whichever ends first:
• 18 months after shipment from our factory
• 12 months after delivery to a specified location
2. Scope of Warranty
If an obvious manufacturing defect is found during the above period under an appropriate condition of
use, IAI will repair the defect free of charge. Note, however, that the following items are excluded from
the scope of warranty:
• Aging such as natural discoloration of coating
• Wear of a consumable part due to use
• Noise or other sensory deviation that doesn’t affect the mechanical function
• Defect caused by inappropriate handling or use by the user
• Defect caused by inappropriate or erroneous maintenance/inspection
• Defect caused by use of a part other than IAI’s genuine part
• Defect caused by an alteration or other change not approved by IAI or its agent
• Defect caused by an act of God, accident, fire, etc.
The warranty covers only the product as it has been delivered and shall not cover any losses arising in
connection with the delivered product. The defective product must be brought to our factory for repair.
Please read the above conditions of warranty carefully.
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1.6 Transportation and Handling
1.6.1 Handling before Unpacking
Exercise due caution when transporting or handling the box containing the actuator, by not applying
impact on the box as a result of collision or dropping.
• If the box is heavy, one person should not carry it by himself.
• Place the box in a level surface.
• Do not step on the box.
• Do not place on the box any heavy object that may cause the box to deform or other object with a
section where loads will concentrate.
1.6.2 Handling after Unpacking
Once removed out of the box, hold the actuator by the frame if it is a rod type, or by the base if it is a slider
type.
• When carrying the actuator, be careful not to allow it to collide with other objects. In particular, pay
attention to the front bracket, motor bracket and motor cover.
• Do not exert excessive force on each part of the actuator. In particular, pay attention to the motor cover
and cables.
• When unpacking, exercise due caution not to let the actuator drop and sustain damage to its
mechanism.
• If the actuator is damaged during the shipment or any of the items is found missing, please contact IAI’s
Technical Support immediately.
Supplement) Refer to 2.1, “Name of Each Part,” for the name of each part of the actuator.
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1.7 Installation Environment and Noise Elimination
Pay due attention to the installation environment of the controller.
1.7.1 Installation Environment
The installation environment must satisfy the following conditions:
No. Use environment/condition
[1] Not exposed to direct sunlight.
The actuator is not subject to irradiated heat from a large heat source, such as a heat
[2]
treatment furnace.
[3]
Ambient temperature of 0 to 40°C.
[4] Humidity of 85% or less without condensation.
[5] Not exposed to corrosive or flammable gases.
[6] Normal environment for assembly and operation not subject to significant dust.
[7] Not exposed to oil mist or cutting fluid.
[8] Not subject to vibration exceeding 0.3 G.
[9] Not exposed to strong electromagnetic waves, ultraviolet light or radiation.
[10] Chemical resistance is not considered at all in the design of this product.
[11] The actuator and cables are not subject to electrical noise.
In general, the installation environment shall be such that the operator can work without wearing any
protective gears.
1.7.2 Storage Environment
The storage environment shall conform to the installation environment, but special caution is required to
prevent condensation if the actuator is to be stored for a long period of time.
Unless otherwise specified, the actuator is shipped without any desiccating agent placed in the box. If the
actuator is to be stored in an environment subject to condensation, provide a non-condensing measure
from outside the box or directly inside the box.
The actuator is designed to withstand storage temperatures of up to 60°C for a short period of time. If the
storage period will extend beyond one month, however, keep the ambient temperature below 50°C.
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1.7.3 Power Supply
The control/motor-drive power supply specification is 24 VDC ± 10% (2 A max).
1.7.4 Noise Elimination
This section explains how to eliminate noise in the use of the controller.
(1) Wiring and power supply
[1] Provide a dedicated class D grounding using a wire with a size of 0.75 mm
Actuator with
integrated
controller
Other
equipment
Actuator with
integrated
controller
Class D grounding Good Avoid this grounding method.
[2] Precautions regarding wiring method
Separate the controller cables from high-power lines such as a cable connecting to a power circuit.
(Do not bundle together the controller cables with high-power lines or place them in the same cable
duct.)
2
or larger.
Other
equipment
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(2) Noise sources and elimination
Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular
concern when building a system. Noise from these sources can be eliminated by implementing the
measures specified below.
[1] AC solenoid valves, magnet switches and relays
Measure: Install a surge absorber in parallel with the coil.
The most effective method is to connect a surge absorber and a surge killer in parallel.
This way, noise will be eliminated in the entire range.
Å Point
Install a surge absorber to each coil over a minimum wiring length.
Installing a surge absorber to the terminal block or other part will
be less effective because of a longer distance from the coil.
Surge absorber
Surge absorber
Surge killer (CR set)
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[2] DC solenoid valves, magnet switches and relays
Measure: Install a diode in parallel with the coil. Determine the diode capacity in accordance with the
load capacity.
Diode
In a DC circuit, connecting a diode in reverse polarity will damage
the diode, internal parts of the controller and/or DC power supply,
so exercise due caution.
1.8 Cabling
• The standard relay cables have excellent flexibility to withstand fatigue from flexural loads, but they are
not robot cables. Therefore, avoid storing the standard relay cables in movable cable ducts laid at a
small radius. If they must be stored in movable cable ducts, use robot cables.
• In an application where the cable cannot be fixed, keep the cable from receiving a deflecting load
exceeding its own weight, use a self-standing cable hose, provide a large bending radius along the
wiring path, or provide other measure to minimize the load applied to the cable.
• Do not cut the cable for the purpose of extension, length reduction or reconnection.
If you intend to change the cable layout, please consult IAI.
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r
2. Installation
2.1 Name of Each Part
2.1.1 Slider Type (SA6/SA7)
Non-motor end
Top
Front bracket
Bottom
2.1.2 Rod Type (RA54/RA64)
Top
Bottom
Non-motor end
Rod
Rod end bracket
Screw cover Coupling bolt
Slider
Base
Right
Left
Rear bracket
Right
Left
Front bracket
Frame
Motor end
Side cove
Motor bracket
Connection port for teaching pendant or PC
(The arrow on the connector should face down.)
Coupling bolt
Connection port for teaching pendant or PC
(The arrow on the connector should face down.)
LED
Rear cover
Motor cover
LED
Rear bracket
Motor bracket
Motor cover Cable
Cable
Motor end
Rear cover
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2.1.3 (1) Rod Type with a Single Guide (RA54GS/RA64GS)
Right
Coupling bolt
Non-motor end
Top
Guide bracket Guide bearing
Left
Guide rod
Rear bracket
Motor bracket
Bottom
Rod
Frame
Connection port for teaching pendant or PC
(The arrow on the connector should face down.)
2.1.3 (2) Rod Type with Double Guides (RA54GD/RA64GD)
Bottom
Mounting bracket
Non-motor end
Guide bracket
Top
Rod
Guide bearing
Guide rod
Right
Coupling bolt
Left
Rear bracket
Frame
Connection port for teaching pendant or PC
(The arrow on the connector should face down.)
LED
Motor cover
LED
Motor bracket
Motor cover
Motor end
Rear cover
Cable
Motor end
Rear cover
Cable
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