PCON-C/CG/CF
Controller
Positioner Type
Operation Manual
Sixth Edition
CAUTION
Changes to Zone Function
Applicable application versions: V0016 and later
Among the zone signal settings, those that result in “Zone setting+ < Zone setting-” are now effective.
V0015 and earlier: “Zone setting+ Zone setting-” A zone signal is not output.
V0016 and later: “Zone setting+ = Zone setting-” This is the only condition in which a zone signal is not
output.
Accordingly, you can now output a zone signal even when a rotary actuator is operated over the 0
position in the index mode.
An example is given below.
[Rotary actuator in index mode]
Set value Set value
Zone setting+: 70 Zone setting+: 315
Zone setting-: 315 Zone setting-: 70
[Linear axis]
Current position
Zone signal output
Zone signal output
Zone signal ON range
Set value
Zone setting+: 70 mm
Zone setting-: 30 mm
Set value
Zone setting+: 30 mm
Zone setting-: 70 mm
CAUTION
1. 24-V Power Supplies Required for UL Certification
PCON controllers (PCON-C/CG, CY, SE, PL/PO) are UL-certified, where one condition for the
certification is to use Class 2 24-V power supplies.
Accordingly, you must use Class 2 power supplies for both the input power supply and I/O power
supply for your equipment incorporating the PCON, if the equipment as a whole must be UL-certified.
2. Use Environment
PCON controllers can be used in an environment of pollution degree 2 or equivalent.
3. PC Software and Teaching Pendant Models
New functions have been added to the entire PCON controller series.
To support these new features, the communication protocol has been changed to the general
Modbus (Modbus-compliant) mode. As a result, the existing PC software programs and teaching
pendants compatible with RCP2 controllers can no longer be used.
If you are using this controller, use a compatible PC software program and/or teaching pendant
selected from the following models.
Model Remarks
PC software RCM-101-***
Teaching pendant CON-T, RCM-T
Simple teaching pendant RCM-E
Data setting unit RCM-P
Touch panel display RCM-PM-01 Not compatible with RCP2 controllers
4. Recommendation for Backing up Latest Data
This product 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.
All are compatible with existing RCP2
controllers
CAUTION
5. Initial Parameter Settings at Startup
After applying power, at least the three parameters specified below must be set in accordance with
the specific application.
Inappropriate settings of these parameters will prevent the controller from operating properly, so
exercise due caution.
For details on how to set the parameters, refer to “Parameter Settings” in the operation manual for
the PC or teaching pendant.
[1] Selecting the PIO pattern
This controller provides six PIO pattern types to meet the needs of various applications.
To select a desired type, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern
selection).
The factory setting is “0 [Standard type].”
Parameter No.
25 setting
0 Standard type
A basic type supporting 64 positioning points and two zone outputs.
* How to set zone boundaries within which to output a zone signal:
Zone boundaries are set using parameter Nos. 1 and 2 for one zone output, and in
the position table for another zone output.
Feature of PIO pattern
1 Teaching type
In this type, 64 positioning points and one zone output (boundaries are set in the
position table) are supported.
In addition to the normal positioning mode, the user can also select the teaching
mode in which the actuator can be jogged via commands from a PLC and the
current actuator position can be written to a specified position.
(Note 1) Jog commands from a PLC are also accepted in the positioning mode.
(Note 2) Positions can be rewritten by approximately 100,000 times.
2 256-point positioning type
The number of positioning points is increased to 256, so only one zone output is
available (boundaries are set in the position table).
3 512-point positioning type
The number of positioning points is increased to 512, so no zone output is available.
4 7-point type
The number of positioning points is limited to seven to offer separate direct
command inputs and position complete outputs for respective positions.
PLC ladder sequence circuits can be designed easily.
5 3-point type
Use of the controller as an air cylinder is assumed in this type.
Position complete output signals function differently in this type, compared to the 7point type.
Specifically, the signal functions not only to “indicate position complete,” but also to
“detect a position” in the same manner as auto-switches of an air cylinder.
CAUTION
[2] Enabling/disabling the servo ON input signal (SON)
The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side.
Depending on the needs, therefore, the user must enable/disable this signal.
To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection).
Enable (use) 0
Disable (do not use) 1
The factory setting is “0 [Enable].”
[3] 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 parameter No. 15 (Pause input disable selection).
Enable (use) 0
Disable (do not use) 1
The factory setting is “0 [Enable].”
6. Using a Rotary Actuator in Multi-rotation Specification
Rotary actuators of multi-rotation specification models let you select multi-rotation operation or limitedrotation operation using a parameter.
6.1 Notes
Pay attention to the setting of the PIO pattern parameter for the controllers specified below.
Each controller does not support relative coordination specification in the PIO pattern specified.
[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25)
[2] PCON-CY: PIO pattern = 0 (User parameter No. 25)
The index mode cannot be selected for rotational axes of simple absolute unit specification.
Accordingly, these axes cannot be specified for multi-rotation specification.
6.2 Applicable Models
Actuators
RCP2-RTBL-I-28P-20-360-* PCON-C-28PI-*
RCP2-RTBL-I-28P-30-360-* PCON-CG-28PI-*
RCP2-RTCL-I-28P-20-360-* PCON-CY-28PI-*
RCP2-RTCL-I-28P-30-360-*
Controllers
PCON-SE-28PI-*
CE Marking
1 European Union EC Directive
The European Union EC Directive was issued for the products to be distributed in EU (European Union)
region to protect the health and secure the safety of the users and consumers of the products. It aims at the
respect and satisfaction of the new approach directive issued by the European Commission and security of
the free distribution of the products within the EU region. Accordingly, the corporations related to the export to
or having any production base in EU countries, have to conform to the conditions for the CE Marking as the
essential condition.
(1) Low Voltage Directive
ACON and PCON have been designed to comply with the low voltage directive as a single unit.
(2) EMC Directive
For the EMC Directive, the subjects are all components including the control units and electric and
electronic components used in the controller and equipment manufactured by our company. We have
determined the connection and installation model (conditions) for the controllers, actuators and
peripheral components and demonstrated the compliance with the standards related to the EMC
Directive using the above model.
2 Applicable Standards
<Low Voltage Directive>
EN 50178 (Electronic Equipment used in Electrical Facility)
<EMC Directive>
EN55011 (Radio Interference for Industrial, Scientific or Medical Radio-Frequency Equipment)
EN61000-6-2 (Industrial Environment Immunity)
EN61000-4-2 (Electro-Static Discharge Immunity)
EN61000-4-3 (Radiated, Radio-Frequency, Electromagnetic Field Immunity)
EN61000-4-5 (Electrical First Transient/Burst Immunity Test)
EN61000-4-5 (Surge Immunity Test)
EN61000-4-6 (Immunity Test to Conducted Disturbances, Induced by Radio-Frequency Fields)
EN61000-4-8 (Power-Frequency Magnetic Field Immunity Test)
3 Peripheral Unit Configuration
Control Board
AC Power Bus
Circuit
Breaker
*R • A • V-781BW7-4 (Maker : OKAYA ELECTRIC INDUSTIES)
Earth
Leakage
Breaker
Surge
Protector*
DC24V
Power
Supply
Power
Te rminal
FG
Fixing using
the Main Body
Set Bolt
(1) Environments
Use the ACON or PCON under the environment with the contamination level 2 or 1 specified in IEC60664-1.
For example, it is installed on the control board with the structure (IP54) where water, oil, carbon or dust
is not entered.
(2) Power Unit
A) Use it under the environment with the Overvoltage Category II specified in IEC60664-1. For this
purpose, make sure to install the breaker for the wiring between the distribution panel and DC24V
power unit.
B) Use the DC24V power unit conforming to CE marking.
(3) Grounding
Make sure to connect the FG earth terminal for ACON or PCON and protective earth (earth plate) for the
control board to avoid electric shock.
(4) Earth Leakage Breaker
Install the earth leakage breaker (BCD) between the distribution panel and DC24V power unit.
(5) Surge Protector
Install the surge protector on the primary side of the DC24V power unit.
Maker : OKAYA ELECTRIC INDUSTRIES CO. , LTD.
Model Name: R x A x V-781BW7-4
Resin
Case
Wire to be taken out
Surge Protector External View
(6) Cable
For all the cables, such as the motor cable, encoder cable and various network cables to be connected to
ACON or PCON, use them with the length less than 30m.
Safety Precautions (Please read before using the product.)
Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as
well as the operating manuals and other related documentations for all equipment and peripheral devices
connected to this product in order to ensure the correct use of this product and connected
equipment/devices. Those performing installation, operation, maintenance and inspection of the product
must have sufficient knowledge of the relevant equipment and their safety. The precautions provided
below are designed to help you use the product safely and avoid bodily injury and/or property damage.
In this operating manual, safety precautions 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
It should be noted that the instructions under the Caution and Note headings may also lead to
serious consequences, if unheeded, depending on the situation.
All instructions contained herein provide vital information for ensuring safety. Please read the contents
carefully and handle the product with due caution.
Please keep this operating manual in a convenient place for quick reference whenever needed, and also
make sure that the manual will get to the end-user.
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.
Danger
[General]
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]
Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The
product may ignite, burn or explode.
Avoid using the product in a place where the main unit or controller may come in contact with water or
oil droplets.
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]
Do not allow the product to come in contact with water. If the product contacts water or is washed with
water, it may operate abnormally and cause injury, electric shock, fire, etc.
[Maintenance, Inspection, Repair]
Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in
injury, electric shock, fire, etc.
Do not disassemble and reassemble the product. Doing so may result in injury, electric shock, fire, etc.
Warning
[General]
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]
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.
Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding:
Grounding resistance at 100 or less). Leakage current may cause electric shock or malfunction.
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.
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]
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.
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.
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.
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.
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.
If the LEDs on the product do not illuminate after turning on the power, turn off the power immediately.
The protective device (fuse, etc.) on the live side may remain active. Request repair to the IAI sales
office from which you purchased the product.
[Maintenance, Inspection, Repair]
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]
Do not throw the product into fire. The product may burst or generate toxic gases.
Caution
[Installation]
Do not use the product under direct sunlight (UV ray), in a place exposed to dust, salt or iron powder,
in a humid place, or in an atmosphere of organic solvent, phosphate-ester machine oil, etc. 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.
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.
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
Do not install the product in a place subject to large vibration or impact. Doing so may result in the
malfunctioning of the product.
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.
Provide sufficient maintenance space when installing the product. Routine inspection and maintenance
cannot be performed without sufficient space, which will eventually cause the equipment to stop or the
product to sustain damage.
Always use IAI’s genuine cables for connection between the controller and the actuator. Also use IAI’s
genuine products for the key component units such as the actuator, controller and teaching pendant.
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.
[Operation]
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.
Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.
[Maintenance, Inspection, Repair]
Do not touch the terminals when performing an insulation resistance test. Electric shock may result.
(Do not perform any withstand voltage test, since the product uses DC voltage.)
Note
[Installation]
Do not place objects around the controller that will block airflows. Insufficient ventilation may damage
the controller.
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.
[Installation, Operation, Maintenance]
When handling the product, wear protective gloves, protective goggles, safety shoes or other
necessary gear to ensure safety.
[Disposal]
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.”
Table of Contents
1. Overview ................................................................................................................... 1
1.1 Introduction.................................................................................................................................. 1
1.2 How to Read the Model Specification.......................................................................................... 2
1.3 System Configuration .................................................................................................................. 3
1.3.1 Internal Drive-Power Cutoff
1.3.2 External Drive-Power Cuto
1.4 Procedure from Unpacking to Test Operation and Adjustment ................................................... 5
1.5 Warranty Period and Scope of Warranty..................................................................................... 7
2. Specifications ............................................................................................................ 8
2.1 Basic Specifications..................................................................................................................... 8
2.2 Name and Function of Each Part of the Controller ..................................................................... 9
2.3 External Dimensions...................................................................................................................11
Relay Type (PCON-C/CF) .......................................... 3
ff Relay Type (PCON-CG) ............................................ 4
3. Installation and Noise Elimination............................................................................ 12
3.1 Installation Environment ............................................................................................................ 12
3.2 Power Supply ............................................................................................................................ 12
3.3 Noise Elimination and Grounding.............................................................................................. 12
3.4 Heat Radiation and Installation.................................................................................................. 14
4. Wiring ...................................................................................................................... 15
4.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)............................................................. 15
4.1.1 External Connection Diagram ............................................................................... 15
4.1.2 Wiring the Power Supply/E
4.2 External Drive-Power Cutoff Relay Type (PCON-CG) .............................................................. 23
4.2.1 External Connection Diagram ............................................................................... 23
4.2.2
4.3 Connecting the I/O Cables ........................................................................................................ 27
PIO pattern 0 [Standard Type] ............................................................................................. 27
PIO pattern 1 [Teaching Type] ............................................................................................. 28
PIO pattern 2 [256-piont mode]............................................................................................ 29
PIO pattern 3 [512-piont mode]............................................................................................ 30
PIO pattern 4 [Solenoid valve mode 1] ................................................................................ 31
PIO pattern 5 [Solenoid valve mode 2] ................................................................................ 32
4.4 Connecting the Actuator ............................................................................................................ 34
Wiring the Power Supply/E
4.4.1 Connecting the PCON-C/C
4.4.2 Connecting the PCON-CF and Actuator............................................................... 36
4.5 Connecting the Communication Cable...................................................................................... 37
mergency-Stop Switch ............................................... 16
mergency-Stop Switch ............................................... 24
G and Actuator........................................................... 34
5. I/O Signal Control and Signal Functions.................................................................. 38
5.1 Interface Circuit ......................................................................................................................... 38
5.1.1 External Input Specifications................................................................................. 38
5.1.2 External Output Specifications.............................................................................. 39
5.2 PIO Patterns and Signal Assignments ...................................................................................... 40
5.2.1 Explanation of Signal Names................................................................................ 41
PIO pattern = 0: Positioning mode [Standard type].............................................................. 41
PIO pattern = 1: Teaching mode [Teaching type] ................................................................ 42
PIO pattern = 2: 256-point mode [256-point type]................................................................ 43
PIO pattern = 3: 512-point mode [512-point type]................................................................ 44
PIO pattern = 4: Solenoid valve mode 1 [7- point type] ....................................................... 45
PIO pattern = 5: Solenoid valve mode 2 [3-point type] ........................................................ 46
5.2.2 Signal Assignment Table for Respective PIO Patterns ......................................... 47
5.3 Details of I/O Signal Functions .................................................................................................. 48
5.3.1. Details of Each Input Signal.................................................................................. 48
Operating mode (RMOD) ..................................................................................................... 48
Start (CSTR) ................................................................................................................ 48
Command position number (PC1 to PC256)........................................................................ 48
Pause (*STP)........................................................................................................................ 49
Home return (HOME) ........................................................................................................... 49
Servo ON (SON)................................................................................................................... 49
Alarm reset (RES) ................................................................................................................ 49
Brake release (BKRL) .......................................................................................................... 50
Operation mode (MODE) ..................................................................................................... 50
Current-position write (PWRT) ............................................................................................. 50
Manual operation switching (JISL) ....................................................................................... 50
Jog (JOG+, JOG-) ................................................................................................................ 51
Direct position command (ST0 to ST6) [7-point type] .......................................................... 51
Movement to each position (ST0 to ST2) [3-point type]....................................................... 52
5.3.2 Details of Each Output Signal
Operating mode status (RMDS)........................................................................................... 53
Completed position number (PM1 to PM256) ...................................................................... 53
Moving (MOVE).................................................................................................................... 53
Position complete (PEND).................................................................................................... 53
Home return completion (HEND) ......................................................................................... 54
Zone (ZONE1, ZONE2)........................................................................................................ 54
Current operation mode (MODES)....................................................................................... 54
Write completion (WEND) .................................................................................................... 54
Movement complete at each position (PE0 to PE6) [7-point type]....................................... 55
Position detection output at each position (LS0 to LS2) [3-point type] ................................ 55
Ready (SV)........................................................................................................................... 55
Alarm (*ALM)........................................................................................................................ 55
Emergency stop (*EMGS).................................................................................................... 56
Load output judgment status (LOAD)................................................................................... 56
Torque level status (TRQS) ................................................................................................. 56
Output Signal Changes in Each Mode ................................................................................. 56
............................................................................... 53
6. Data Entry <Basics>................................................................................................ 57
6.1 Description of Position Table ..................................................................................................... 57
6.1.1 Relationship of Push Force at St
Slider type..................................................................................................................... 61
(1) SA5C/SA6C/SS7C type................................................................................... 61
(2) SA7C type........................................................................................................ 61
andstill and Current-Limiting Value .................... 61
(3) SS8C type........................................................................................................ 62
Rod type ....................................................................................................................... 63
(1) RA2C type........................................................................................................ 63
(2) RA3C type........................................................................................................ 63
(3) RA4C type........................................................................................................ 64
(4) RA6C type........................................................................................................ 64
(5) RA10C/W-RA10C type .................................................................................... 65
6.2 Explanation of Modes ................................................................................................................ 66
6.2.1 Positioning Mode .................................................................................................. 66
6.2.2 Push & Hold Mode................................................................................................ 66
6.2.3
6.2.4 S
6.2.5
Torque Check Function in Push & Hold Operation ............................................... 68
peed Change during Movement ......................................................................... 70
Operation at Different Acce
leration and Deceleration Settings ............................. 70
6.2.6 Pause ................................................................................................................... 71
6.2.7 Zone
Signal Output............................................................................................... 71
6.2.8 Home Return ........................................................................................................ 72
6.2.9 Ov
erview of Teaching T
6.2.10 Overview of 7-point Ty
6.2.11 Overview of 3-point Ty
6.3 Notes on the ROBO Gripper...................................................................................................... 78
6.4 Power-saving Modes at Standby Positions ............................................................................... 80
6.5 Using a Rotary Actuator in Multi-rotation Specification.............................................................. 83
ype................................................................................... 73
pe ...................................................................................... 74
pe ...................................................................................... 76
6.5.1 How to Use ........................................................................................................... 83
7. Operation <Practical Steps>.................................................................................... 84
7.1 How to Start............................................................................................................................... 84
7.1.1 Timings after Power On ........................................................................................ 84
Procedure after initial startup until actuator adjustment .................................................... 84
Procedure of Normal Operation......................................................................................... 86
7.1.2 Position Table and Parameter Settings Required for Operation ........................... 88
Startup adjustment............................................................................................................. 88
Safety speed during manual feed...................................................................................... 88
Speed override for movement commands from the PLC .................................................. 88
Full-scale operation ........................................................................................................... 89
Saving energy when the actuator stands by for a long time after the power has been
turned on............................................................................................................................ 89
Saving energy when the actuator stands by after completing the home return operation
effected by the HOME input signal .................................................................................... 89
Saving energy when the actuator stands by for a long time at the target position............ 89
Output mode of complete signal ........................................................................................ 89
7.2 Home Return Operation ............................................................................................................ 90
7.2.1 Method Using the HOME Input Signal (PIO Pattern = 0 to 4)............................... 90
7.2.2 Method Used When No HOME Input Signal Is
7.3 Positioning Mode (Back and Forth Movement between Two Points)........................................ 93
7.4 Push & Hold Mode..................................................................................................................... 95
7.4.1 Return Action after Push & Hold by Relativ
7.5 Speed Change during Movement.............................................................................................. 98
7.6 Operation at Different Acceleration and Deceleration Settings ............................................... 100
7.7 Pause....................................................................................................................................... 102
Available (PIO Pattern = 5).......... 92
e Coordinate Specification................. 97
7.8 Zone Signal Output.................................................................................................................. 104
7.9 Incremental Moves .................................................................................................................. 107
7.9.1 Judgment Method of End Position...................................................................... 109
7.9.2
7.10 Jogging/Teaching Using PIO ....................................................................................................113
7.11 Operation in 7-point Type .........................................................................................................115
7.12 Operation in 3-point Type .........................................................................................................119
Notes on Increment
al Mode.................................................................................110
8. Parameters............................................................................................................ 123
8.1 Parameter Table ...................................................................................................................... 123
8.2 Detail Explanation of Parameters............................................................................................ 125
8.2.1 Parameters Relating to the Actuator Stroke Range ............................................ 125
Soft limit ...................................................................................................................... 125
Software limit margin .................................................................................................. 125
Zone boundary .......................................................................................................... 126
Home return direction ............................................................................................... 127
Home return offset...................................................................................................... 127
8.2.2 Parameters Relating to the Actuator Operating Characteristics
PIO jog speed ............................................................................................................. 127
PIO inching distance................................................................................................... 127
Default speed.............................................................................................................. 127
Default acceleration/deceleration ............................................................................... 128
Default positioning band ........................................................................................... 128
Current-limiting value at standstill during positioning ................................................. 128
Current-limiting value during home return .................................................................. 128
Home sensor input polarity......................................................................................... 128
Speed override ........................................................................................................... 128
Default direction of excited-phase signal detectio...................................................... 129
Excited-phase signal detection time ........................................................................... 129
Safety speed ............................................................................................................. 129
Automatic servo-off delay time ................................................................................. 130
Default standstill mode .............................................................................................. 130
Push speed ............................................................................................................... 131
Push completion judgment time ................................................................................. 131
Enable function........................................................................................................... 132
Polarity of home check sensor input ......................................................................... 132
Load output judgment time ......................................................................................... 132
Torque check range .................................................................................................. 133
Ball screw lead length ............................................................................................... 133
Axis operation type ................................................................................................... 133
Rotational axis mode selection................................................................................... 133
Shortcut selection for rotational axis........................................................................... 133
Absolute unit ............................................................................................................... 134
Current-limiting value at standstill after missing work in push & hold operation ........ 134
8.2.3 Parameters Relating to the External Interface
PIO pattern selection ................................................................................................ 135
Movement command type .......................................................................................... 136
Pause input disable selection ................................................................................... 137
Servo ON input disable selection .............................................................................. 137
Home-return input disable selection........................................................................... 137
Operating-mode input disable selection ..................................................................... 137
Output mode of position complete signal ................................................................... 138
SIO communication speed.......................................................................................... 138
.................................................... 135
.......................... 127
Minimum delay time for slave transmitter activation ................................................. 138
Silent interval multiplier............................................................................................... 139
8.2.4 Servo Gain Adju
Servo gain number .................................................................................................... 140
Speed loop proportional gain...................................................................................... 140
Speed loop integral gain............................................................................................. 141
Torque filter time constant .......................................................................................... 141
stment ....................................................................................... 140
9. PC/Teaching Pendant Connection Method in Multi-axis Configurations................ 142
9.1 Connection Example ............................................................................................................... 142
9.2 SIO Converter (Optional)......................................................................................................... 143
9.3 Address Switch........................................................................................................................ 145
9.4 Connection Cables .................................................................................................................. 145
9.5 Detail Connection Diagram...................................................................................................... 146
10. Troubleshooting..................................................................................................... 147
10.1 Action to Be Taken upon Occurrence of Problem ................................................................... 147
10.2 Alarm Level Classification ....................................................................................................... 148
10.3 Alarm Description Output Using PIO....................................................................................... 149
10.4 Alarm Description and Cause/Action....................................................................................... 150
(1) Message level alarms......................................................................................................... 150
(2) Cold-start level alarms........................................................................................................ 155
10.5 Messages Displayed during Operation Using the Teaching Pendant ..................................... 157
10.6 Specific Problems.................................................................................................................... 160
I/O signals cannot be exchanged with the PLC. ................................................................ 160
The ALM lamp illuminates when the power is input........................................................... 160
The SV lamp does not illuminate when the servo ON signal is input after the power was
input.................................................................................................................................... 160
Home return ends in the middle in a vertical application. .................................................. 161
Noise occurs during downward movements in a vertical application................................. 161
Vibration occurs when the actuator is stopped. ................................................................. 161
The actuator overshoots when decelerated to a stop........................................................ 161
The home and target positions sometimes shift................................................................. 161
The speed is slow during push & hold operation. .............................................................. 161
The actuator moves only a half of, or twice as much as, the specified movement............ 161
A servo error occurred while the actuator was moving (ROBO Gripper)........................... 162
Abnormal operation results when the servo is turned ON after the power ON.................. 163
The SV lamp blinks. ........................................................................................................... 163
* Appendix ................................................................................................................... 164
List of Supported Actuator Specifications .......................................................................................... 164
Fault check and replacement of the cooling fan ................................................................................ 177
Example of Basic PCON Positioning Sequence................................................................................ 179
Recording of Parameters................................................................................................................... 182
1. Overview
1.1 Introduction
This product is a dedicated RCP2 / RCP3 actuator controller that provides the same functions of the
RCP2 controller as well as a set of new functions designed to achieve greater convenience and safety.
The product also provides a power-saving function in response to growing energy-saving needs.
The key features and functions are listed below.
More positioning points
The standard type supports up to 64 points, while the extended types can handle up to 512 points.
Availability of more positioning points is ideal for production lines where many types of products are
produced in small volumes.
Setting of zone output boundaries for each position in the position table
Before, zone output boundaries were set by parameters and therefore fixed. To add flexibility, new
fields have been added to the position table so that different boundaries can be set for each position.
This feature is useful in preventing contact with surrounding equipment and reducing the tact time,
among others.
Separate acceleration/deceleration settings
Acceleration and deceleration are now set in separate fields of the position table.
Depending on the material or shape of the load, it is desirable to reduce shock and vibration when the
actuator stops.
Since acceleration and deceleration can be set differently, only the deceleration value can be reduced
to make the deceleration curve more gradual.
Limitation of feed speed in test operation and adjustment
The feed speed to be used in test operation and adjustment can be limited for added safety.
Power-saving measures
In general, pulse motors consume more holding current in standstill state than AC servo motors. This
product provides a power-saving means to support situations where the actuator must stand by for a
long period.
When actually starting up your system or if you have encountered any problem, also refer to the operation
manuals for the actuator, teaching pendant, PC software and other components used with the system, in
addition to this manual.
This manual does not cover all possible operations other than normal operations, or unexpected events
such as complex signal changes resulting from use of critical timings.
Accordingly, you should consider items not specifically explained in this manual as “prohibited.”
* We have made every effort to ensure precision 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 How to Read the Model Specification
<Series>
<Type>
C: Positioner type with internal drive-
power cutoff relay
CG: Positioner type with external drive-
power cutoff relay
CF: High-output positioner type with internal
drive-power cutoff relay
<Actuator type>
[Motor flange size]
20P: 20, square
28P: 28, square
28SP: 28, square (RA3 type only)
42P: 42, square
56P: 56, square
86P: 86 square
[Encoder type]
I: Incremental
Specified for connecting the
simple absolute unit
<Power-supply voltage>
0: 24 VDC
<I/O flat cable length>
0: No cable
2: 2 m
3: 3 m
5: 5 m
<Input/output signal pattern>
NP: NPN (Sink type)
PN: PNP (Source type)
DV: DeviceNet connection specification
CC: CC-Link connection specification
PR: PROFIBUS connection specification
CN: CompoNet connection specification
ML: MECHATROLINK connection
2
1.3 System Configuration
1.3.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)
RS232C type <RCM-101-MW>
USB type <RCM 101-USB>
PC software
(optional)
Standard teaching
<CON-T, RCM-T>
PC
pendant
PERSONAL
COMPUTER
Input power
supply
24 VDC
Supplied flat
cable
RCP2 actuator
External EMG switch
24 V
0 V
Host system <PLC>
24-VDC I/O
power supply
Caution: Connect one end of the EMG switch to the 24-V output of the input power supply and the
other end to the S1 terminal. Also short the S2 and EMG terminals using a jumper wire.
3
1.3.2 External Drive-Power Cutoff Relay Type (PCON-CG)
RS232C type <RCM-101-MW>
USB type <RCM 101-USB>
PC software
(optional)
PC
Standard teaching
PERSONAL
COMPUTER
pendant
<RCM-T>
Input power
supply 24
VDC
Supplied flat
cable
RCP2 actuator
Motor drivepower cutoff
circuit
Safety relay
Contactor
Host system <PLC>
24-VDC I/O
power supply
S1
S2
MPI
MPO
24V
0V
EMG-
4
1.4 Procedure from Unpacking to Test Operation and Adjustment
If you are using this product for the first time, carry out each step by referring to the procedure below to
ensure that all necessary items are checked and all wires are connected correctly.
Check the content in the package
1
If you found any missing part or part specified for a different model, please contact your dealer.
Controller
PCON-C
PCON-CG
PCON-CF
Operation manual
<Options>
Teaching pendant PC software
RCM-T (standard) RC232C type <RCM-101-MW>
RCM-E (simple) RC232 type <RCM-101-USB>
RCM-P (data setting unit) (Software comes with connection cables.)
2
Installation
[1] Affix the actuator first, and then install the robot hand. Refer to the operation manual for the
[2] Install the controller. Chapter 3, “Installation”
3
Wiring/connection
Wire the 24-V power supply.
Connect the grounding wire to ground.
Wire the emergency stop circuit and motor drive power supply.
Connect the motor cable and encoder cable.
Connect the I/O flat cable.
Turn on the power and check for alarms
4
Supply the 24-V power after confirming that the emergency stop circuit is not actuated.
If the monitor LED [SV/ALM] on the front face of the controller illuminates for two seconds and then turns
off, the controller is functioning properly. If [SV/ALM] illuminates in red, it means an alarm has generated.
Connect a PC or teaching pendant to check the nature of the alarm, and remove the cause by referring to
Chapter 10, “Troubleshooting.”
Set the PIO pattern/safety speed
5
Set the mode selector switch on the front face of the controller to the “MANU” side.
On the PC screen or teaching pendant, set the MANU operating mode to [Teaching mode: Enable safety
speed/Inhibit PIOs].
In this condition, set appropriate values in parameter No. 25 (PIO pattern selection) and parameter No. 35
(Safety speed).
* The factory-set PIO pattern and safety speed are “standard type” and “100 mm/s or less,” respectively.
Chapter 8, “Parameter Settings”
Actuator I/O flat cable
CB-PAC PIO* * *
Motor cable
CB-RCP2-MA* * *
applicable actuator.
Encoder cable
CB-RCP2-PA* * *
5
6
Turn on the servo
Confirm that the slider or rod is not contacting a mechanical end.
If the slider/rod is contacting a mechanical end, move it away from the mechanical end.
If the actuator is equipped with a brake, turn on the brake forced-release switch to forcibly release the
brake before moving the actuator.
The load may suddenly drop when the brake is released, so exercise due caution not to pinch your hand
or damage the robot hand by the falling load.
Turn on the servo from the PC or teaching pendant.
If the actuator enters a servo lock mode and the monitor LED [SV/ALM] on the front face of the controller
illuminates in green, the controller is functioning properly.
Check the operation of the safety circuit
7
Confirm that the emergency stop circuit (or motor drive-power cutoff circuit) operates properly.
Chapter 4, “Wiring”
Set a target position
8
Perform home return first, and then set a target position in the “Position” field for each position in the
position table. Determine a desired position by finely adjusting the load or robot hand.
* Once a target position is set, all other fields (speed, acceleration/deceleration, positioning band, etc.)
will be automatically populated with their default values. Chapter 6, “Position Table Settings”
* To ensure safety, it is recommended that the safety speed be enabled during initial movements.
To move the actuator at the actual speed set in the “Speed” field of the position table, change the
MANU operating mode to [Teaching mode 2: Disable safety speed/Inhibit PIOs].
Trial operation and adjustment
9
Set the mode selector switch on the front panel of the controller to the “AUTO” side.
Input a movement command from the PLC to perform positioning.
If necessary, perform fine adjustments including the items specified below:
Vibration or noise may generate depending on the weight, material or shape of the load. If vibration or
noise is observed, lower the speed, acceleration and/or deceleration.
To prevent contact with surrounding equipment or reduce the tact time, adjust the boundaries for each
zone output signal and also adjust the positioning band.
Adjust the current-limiting value, judgment time and push speed to be used in push & hold operation.
Caution: Before changing any parameter, set the mode selector switch to the “MANU” side. Or,
keep the mode selector switch on the “AUTO” side and turn on the MODE input signal.
6
1.5 Warranty Period and Scope of Warranty
The controller 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 in the IAI product you have purchased during the above
warranty 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.
Take note that the warranty specified herein covers only the delivered product. Any losses arising from
a failure of the delivered product are excluded from the scope of warranty. Also note that the product
must be brought to the factory for repair.
Please read carefully the above conditions of warranty.
7
2. Specifications
2.1 Basic Specifications
Specification item
(Internal Drive-Power Cutoff
PCON-C
Relay Type)
PCON-CG
(External Drive-Power
Cutoff Relay Type)
Number of controlled axes 1 axis/unit
Supply voltage
Power-source
capacity
Actuator Rated Max. *2 Rated Max. *2 Rated Max. *3
20, 28P motor 0.4 A 0.4 A
35, 42, 56P motor 1.2 A
24 VDC 10%
2.0 A
1.2 A
2.0 A
86P motor 4.2 A 6.0 A
Heat output 9.6 W 9.6 W 26.4 W
Control method Weak field-magnet vector control
Encoder resolution Incremental specification 800 Puls/rev
Positioning command Number of positioning points: 64 points (standard) to 512 points (maximum)
* The number of positioning points varies depending on the selected PIO
pattern.
Backup memory
Position data and parameters are saved in nonvolatile memory.
Serial EEPROM can be rewritten approx. 100,000 times.
PIO interface 24-VDC I/O
LED indicators SV (green) --- Servo on, ALM (red) --- Alarm present
Serial communication RS485, 1 channel (conforming to the Modbus protocol)
Electromagnetic-brake forced
release function
Cable length
NOM/BK RLS switch (front panel)
Actuator cable: 20 m or less
I/O flat cable: 5 m or less
Insulation strength
Environment
Surrounding air
temperature
Surrounding
humidity
Surrounding
environment
Storage
temperature
500 VDC, 10 M
0 to 40C
85%RH or less (non-condensing)
Not subject to corrosive gases.
-10 to 65C
Storage humidity 90%RH or less (non-condensing)
Vibration
resistance
10 to 57 Hz in XYZ directions / Pulsating amplitude: 0.035 mm (continuous),
0.075 mm (intermittent)
57 to 150 Hz in XYZ directions: 4.9 m/s
2
(continuous), 9.8 m/s2
Protection class IP20
Cooling method Natural air cooling Forced air cooling
Weight 300 g or less 30 g or less 300 g or less
External dimensions 35 W x 175.5 H x 68.1 D mm
*1 Rush current of around 5 to 12 times the rated current flows for approx. 1 to 2 msec
after the power is turned on. Take note that the value of rush current varies
according to the impedance of the power-supply line.
*2 Excitation detection operation is performed after the power is turned on. The
maximum current flows during this operation (normally for 100 msec).
Note, however, that approx. 6.0 A of current flows (for approx. 1 to 2 msec) if the
motor drive source is cut off and then turned on again.
*3 Excitation detection operation is performed after the power is turned on. The
maximum current flows during this operation (normally for 100 msec).
Note, however, that approx. 10.0 A of current flows (for approx. 1 to 2 msec) if the
motor drive source is cut off and then turned on again.
For the +24-V DC power supply,
select a unit of the “peak load
accommodation” specification or
having a sufficient allowance with
respect to the peak load. In
particular, exercise caution when
your system has a remote sensing
function.
Caution: Position data, parameters, etc., are written to the EEPROM. Take note
that the EEPROM can be rewritten for up to approx. 100,000 times.
PCON-CF
(Internal Drive-Power
Cutoff Relay Type)
8
A
2.2 Name and Function of Each Part of the Controller
PIO connector
Connects the PLC and PIOs.
Mode selector switch
SIO connector
Connects the teaching
pendant/PC.
The model name of the actuator to
be connected is indicated here.
Motor connector
Connects the motor cable.
Power-supply
terminal block
Indication of PIO pattern number
If you have multiple systems and a different PIO pattern is used for each system, it is recommended
that you specify an applicable PIO pattern number on each controller to prevent confusion.
Explanation of input/output signal pattern
NPN --- Sink type
PNP --- Source type
Explanation of motor drive-power cutoff circuit
INT --- PCON-C/CF [Internal drive-power cutoff relay type]
EXT --- PCON-CG [External drive-power cutoff relay type]
Indication of model name of actuator to be connected
The type name, ball screw lead length and stroke of the applicable actuator are indicated. When
connecting the cables, check this information to confirm that they are connected to the correct actuator.
Example of indication:
RA4C
L: 5 mm
ST: 200
The actuator type is RA4C.
The ball screw lead length is 5 mm.
The stroke is 200 mm.
Status indicator LEDs
SV (green) --- The servo is on
A blinking green light indicates
that the automatic servo-off
mode is active.
LM (red) --- An alarm is present.
The motor drive-power cutoff
circuit is indicated here.
The PIO pattern number is specified here.
The input/output signal pattern is indicated
here.
Address switch
Encoder connector
Connects the encoder cable.
Brake release switch
9
Explanation of each switch
[1] Address switch
If multiple axes are used, the PC/teaching pendant must be plugged into/out of different connectors
to communicate with different axes.
To save the hassle, you can use link cables to connect all axes via SIO converters.
Under this method, however, the PC/teaching pendant must be able to identify each axis by the
number assigned to the axis.
This switch is used to set this number.
For details, refer to Chapter 9, “How to Connect a PC/Teaching Pendant to Multiple Axes.”
[2] Mode selector switch
This interlock switch is used to prevent unexpected movement or data rewrite as a result of duplicate
operation in which a movement command is input from the PLC and operation using the PC/teaching
pendant is performed at the same time.
AUTO: Always set to the “AUTO” side during auto operation using PIO signals from the PLC.
MANU: Always set to the “MANU” side during operation using the PC/teaching pendant.
[3] Brake release switch
When the actuator is equipped with a brake, this switch is used to forcibly release the brake.
RLS: Forcibly release the brake
NOR: Normal setting (The brake is released by the controller.)
Warning: The load may suddenly drop when the brake is forcibly released, so exercise due caution
not to pinch your hand or damage the robot hand by the falling load.
Explanation of power-supply terminal block
[1] PCON-C/CF [Internal drive-power cutoff relay type]
Provide a contact output for the emergency-stop button on the teaching pendant.
S1, S2
* Whether or not a teaching pendant is connected is determined by an internal
circuit. If no teaching pendant is connected, the S1 and S2 terminals are closed.
Provide a contact for cutting off the motor drive power. MPI and MPO represent the
MPI, MPO
input side and output side of the motor power supply, respectively. (Short these
terminals using a jumper wire if not used. The controller is shipped with MPI and MPO
shorted.)
24V Positive side of the 24-VDC input power supply
0V Negative side of the 24-VDC input power supply
EMG- Emergency-stop input
[2] PCON-CG [External driver-power cutoff relay type]
Provide a contact output for the emergency-stop button on the teaching pendant.
S1, S2
* Whether or not a teaching pendant is connected is determined by an internal
circuit. If no teaching pendant is connected, the S1 and S2 terminals are closed.
Motor drive-power cutoff contacts conforming to safety category 1
MPI, MPO
MPI and MPO represent the input side and output side of the motor power supply,
respectively. (Connect an external safety circuit.)
24V Positive side of the 24-VDC input power supply
0V Negative side of the 24-VDC input power supply
EMG- Emergency stop signal detection
10
2.3 External Dimensions
An external view and dimensions of the product are shown below.
5
(Mounting dimension)
11
3. Installation and Noise Elimination
Pay due attention to the installation environment of the controller.
3.1 Installation Environment
(1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient
ventilation will not only prevent the controller from demonstrating its full performance, but it may also
cause breakdown.)
(2) Prevent foreign matter from entering the controller through the ventilation holes. Since the enclosure
of the controller is not dustproof or waterproof (oilproof), avoid using the controller in a place subject
to significant dust, oil mist or splashes of cutting fluid.
(3) Do not expose the controller to direct sunlight or radiating heat from a large heat source such as a
heat treatment furnace.
(4) Use the controller in an environment free from corrosive or inflammable gases, under a temperature
of 0 to 40C and humidity of 85% or less (non-condensing).
(5) Use the controller in an environment where it will not receive any external vibration or shock.
(6) Prevent electrical noise from entering the controller or its cables.
3.2 Power Supply
The power supply specification is 24 VDC 10%.
(Supply current: 2 A max.: C/CG, 6 A: CF)
3.3 Noise Elimination and Grounding
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 2.0 to 5.5 mm2 or larger.
Controller
Use a cable of a
maximum possible
size and keep the
wiring length at a
minimum.
Metal frame
Class D grounding Good Avoid this grounding method.
Other
equipment
Controller
Other
equipment
12
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