IAI America ERC User Manual

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ERC Actuator with Integrated Controller

Operation Manual Seventh Edition

Please Read Before Use

Thank you for purchasing our product.

This Operation Manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely.

Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The CD that comes with the product contains operation manuals for IAI products. When using the product, refer to the necessary portions of the applicable operation manual by printing them out or displaying them on a PC.

After reading the Operation Manual, keep it in a convenient place so that whoever is handling this product can reference it quickly when necessary.

[Important]

 This Operation Manual is original.  The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI shall

assume no responsibility for the outcome of any operation not specified herein.

 Information contained in this Operation Manual is subject to change without notice for the purpose of

product improvement.

 If you have any question or comment regarding the content of this manual, please contact the IAI sales

office near you.

 Using or copying all or part of this Operation Manual without permission is prohibited.  The company names, names of products and trademarks of each company shown in the sentences are

registered trademarks.

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]

24V

SIO

converter

PLC communication module

Actuator 1

Actuator 2

Actuator 3

Actuator 4

24-V power supply

[5]

24V

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

[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

5. PC Software Versions

This actuator is supported by PC software version 4.0.0.0 or later.

       F3        H3        H3        B2

Safety Guide ........................................................................................................ 1

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

1.3.3 Sound Pressure Levels of This Product Will Not Exceed 70 dB. ............................................... 6

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..................................................................................................... 16

2.1 Name of Each Part ...............................................................................................................................16

2.1.1 Slider Type (SA6/SA7) .............................................................................................................. 16

2.1.2 Rod Type (RA54/RA64) ............................................................................................................ 16

2.1.3 (1) Rod Type with a Single Guide (RA54GS/RA64GS) ............................................................ 17

(2) Rod Type with Double Guides (RA54GD/RA64GD)............................................................ 17

2.2 Installation.............................................................................................................................................18

2.2.1 Slider Type ................................................................................................................................ 18

 Installing the actuator ..................................................................................................................... 18

2.2.2 Rod Type................................................................................................................................... 19

 Affixing with a flange....................................................................................................................... 19

 Affixing through holes in a flange ................................................................................................... 19

 Affixing with foot brackets (optional)............................................................................................... 20

2.2.3 Installing the Load..................................................................................................................... 21

 Slider Type...................................................................................................................................... 21

 Rod Type ........................................................................................................................................ 22

 Rod type with a guide(s)................................................................................................................. 22

3. Wiring............................................................................................................ 23

3.1 Basic Structure......................................................................................................................................23

3.2 I/O Connections for PIO Pattern 1 [3 Points] (Air Cylinder)..................................................................26

3.2.1 Explanation of I/O Signals......................................................................................................... 26

3.2.2 Details of Input Signals ............................................................................................................. 27

 Movement to each position (ST0 to ST2) ....................................................................................... 27

 Pause (*STP).................................................................................................................................. 27

3.2.3

Details of Output Signals .......................................................................................................... 28

 Completion of each position (PE0 to PE2) ..................................................................................... 28

 Alarm (*ALM) .................................................................................................................................. 28

3.3

I/O Connections for PIO Pattern 0 [8 Points]........................................................................................29

3.4 I/O Connections for PIO Pattern 2 [16 Points]......................................................................................29

3.4.1 Explanation of I/O Signals......................................................................................................... 30

3.4.2 Details of Input Signals ............................................................................................................. 30

 Start (CSTR) ................................................................................................................................... 30

 Command position number (PC1 to PC8)...................................................................................... 31

 Pause (*STP).................................................................................................................................. 31

 Home return (HOME) ..................................................................................................................... 31

3.4.3

Details of Output Signals .......................................................................................................... 31

 Position complete (PEND).............................................................................................................. 31

 Home return completion (HEND) ................................................................................................... 32

 Zone (ZONE) .................................................................................................................................. 32

 Alarm (*ALM) .................................................................................................................................. 32

3.5

Configuration Using a SIO Converter ...................................................................................................33

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

 Using only a SIO converter............................................................................................................. 44

 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 ....................................... 66

 Slider type.........................................................................................................................................66

(1) SA6 type............................................................................................................................................66

(2) SA7 type............................................................................................................................................66

 Rod type ...........................................................................................................................................67

(1) RA54 type .........................................................................................................................................67

RA64 type .........................................................................................................................................67

(2)

5.2 Explanation of Modes ...........................................................................................................................68

5.2.1 Positioning Mode Push = 0 ....................................................................................................... 68

5.2.2

Push & Hold Mode Push = Other than 0................................................................................... 68

5.2.3 Speed Change during Movement ............................................................................................. 70

5.2.4 Operation at Different Acceleration and Deceleration Settings ................................................ 70

5.2.5 Pause ........................................................................................................................................ 71

5.2.6 Zone Signal Output ................................................................................................................... 71

5.2.7 Home Return............................................................................................................................. 71

6. Operation in the “3 Points (Air Cylinder)” Mode <Practical Operation> ........ 72

6.1 Overview of the “3 Points” Mode ..........................................................................................................72

6.2 How to Start ..........................................................................................................................................74

6.3 Moving Operation .................................................................................................................................76

7. Operation in the “8 Points” and “16 Points” Modes <Practical Operation> ... 80

7.1 How to Start ..........................................................................................................................................80

7.2 How to Execute Home Return ..............................................................................................................82

7.2.1 8 Points ..................................................................................................................................... 82

7.2.2 16 Points ................................................................................................................................... 83

7.3 Home Return and Movement after Start (16 Points) ............................................................................84

7.4 Positioning Mode (Back and Forth Movement between Two Points)...................................................86

7.5 Push & Hold Mode................................................................................................................................88

7.5.1 Return Action after Push & Hold by Relative Coordinate Specification .................................... 89

7.6 Speed Change during Movement.........................................................................................................90

7.7 Operation at Different Acceleration and Deceleration Settings ............................................................92

7.8 Pause....................................................................................................................................................94

7.9 Zone Signal Output...............................................................................................................................96

7.10 Incremental Moves ...............................................................................................................................98

7.11 Notes on Incremental Mode................................................................................................................100

8. Parameters ................................................................................................. 102

8.1 Parameter Classification.....................................................................................................................102

8.2 Parameter Table .................................................................................................................................102

8.3 Parameter Settings .............................................................................................................................103

8.3.1 Parameters Relating to the Actuator Stroke Range................................................................ 103

 Soft limit ........................................................................................................................................ 103

 Zone boundary ............................................................................................................................. 103

 Home return direction ................................................................................................................... 104

 Home return offset ........................................................................................................................ 104

8.3.2

Parameters Relating to the Actuator Operating Characteristics............................................. 104

 Default speed ............................................................................................................................... 104

 Default acceleration/deceleration ................................................................................................. 104

 Default positioning band (in-position) ........................................................................................... 104

 Default acceleration only MAX flag .............................................................................................. 105

 Push & hold stop judgment period ............................................................................................... 105

 Current-limiting value at standstill during positioning ................................................................... 105

 Current-limiting value during home return .................................................................................... 106

 Excited-phase Signal Detection Direction .................................................................................... 106

8.3.3

Parameters Relating to the External Interface........................................................................ 107

 PIO pattern selection .................................................................................................................... 107

 Movement command type ............................................................................................................ 107

 Pause input disable selection ....................................................................................................... 108

 Serial communication speed ........................................................................................................ 108

 Minimum delay time for slave transmitter activation .................................................................... 108

8.3.4

Servo Gain Adjustment ........................................................................................................... 109

 Servo gain number ....................................................................................................................... 109

9. Troubleshooting .......................................................................................... 110

9.1 Action to Be Taken upon Occurrence of Problem...............................................................................110

9.2 Alarm Level Classification...................................................................................................................110

9.3 Alarm Description and Cause/Action.................................................................................................. 111

(1) Message level alarms.................................................................................................................... 111

(2) Operation-cancellation level alarms ..............................................................................................112

(3) Cold-start level alarms...................................................................................................................113

9.4 Messages Displayed during Operation Using the Teaching Pendant or PC Software....................... 114

9.5 Specific Problems ...............................................................................................................................116

 I/O signals cannot be exchanged with the PLC.............................................................................11 6

 The LED lamp does not illuminate after the power is input...........................................................116

 The LED illuminates in red when the power is turned on. .............................................................11 6

 Home return ends in the middle in a vertical application...............................................................116

 Noise occurs during downward movements in a vertical application. ...........................................116

 Vibration occurs when the actuator is stopped..............................................................................11 7

 The actuator overshoots when decelerated to a stop. ..................................................................117

 The home and target positions sometimes shift on the rod-type actuator.....................................117

 The speed is slow during push & hold operation...........................................................................11 7

 The actuator operates abnormally when the servo is turned on following the power on. .............117

10. Maintenance and Inspection....................................................................... 118

10.1 Inspection Items and Timings .............................................................................................................118

10.2 Visual Inspection of Appearance ........................................................................................................118

10.3 Cleaning..............................................................................................................................................118

10.4 Internal Check (Slider Type)...............................................................................................................119

10.5 Internal Cleaning (Slider Type) ...........................................................................................................120

10.6 Greasing the Guide (Slider Type).......................................................................................................120

10.7 Greasing the Ball Screw (Slider Type)................................................................................................122

10.8 Greasing the Rod Slide Surface .........................................................................................................123

10.9 Motor Replacement Procedure...........................................................................................................124

Appendix .......................................................................................................... 126

Example of Basic ERC Positioning Sequence.............................................................................................126

Recording of Position-Data Table.................................................................................................................129

Parameter Records ......................................................................................................................................130

Change History ................................................................................................ 132

Safety Guide

This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property damage. Be sure to read this section before using your product.

Regulations and Standards Governing Industrial Robots

Safety measures on mechanical devices are generally classified into four categories under the International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows:

Safety measures Inherent safety design

Protective guards --- Safety fence, etc. Additional safety measures --- Emergency stop device, etc. Information on use --- Danger sign, warnings, operation manual

Based on this classification, various standards are established in a hierarchical manner under the International Standards ISO/IEC. The safety standards that apply to industrial robots are as follows:

Type C standards (individual safety standards) ISO10218 (Manipulating industrial robots – Safety)

JIS B 8433 (Manipulating industrial robots – Safety)

Also, Japanese laws regulate the safety of industrial robots, as follows:

Industrial Safety and Health Law Article 59

Workers engaged in dangerous or harmful operations must receive special education.

Ordinance on Industrial Safety and Health Article 36 --- Operations requiring special education

No. 31 (Teaching, etc.) --- Teaching and other similar work involving industrial robots (exceptions

apply)

No. 32 (Inspection, etc.) --- Inspection, repair, adjustment and similar work involving industrial robots

(exceptions apply)

Article 150 --- Measures to be taken by the user of an industrial robot

Pre-1

Requirements for Industrial Robots under Ordinance on Industrial Safety and

Health

Work area Work condition Cutoff of drive source Measure Article

Signs for starting operation Article 104 Outside Installation of railings, enclosures, etc. Sign, etc., indicating that work is in progress Preparation of work rules Article 150-3 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education Article 36-31 Checkup, etc., before commencement of work To be performed after stopping the operation Sign, etc., indicating that work is in progress Preparation of work rules Article 150-5 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education (excluding cleaning and lubrication)

Article 150-4

Article 150-3

Article 151

Article 150-5

Article 36-32

movement

range

Inside

movement

range

During automatic operation

During

teaching, etc.

During

inspection, etc.

Not cut off

Cut off (including

stopping of operation)

Not cut off

Cut off

Not cut off

(when inspection, etc.,

must be performed

during operation)

Pre-2

Applicable Modes of IAI’s Industrial Robot

Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No. 340):

(1) Single-axis robo with a motor wattage of 80 W or less (2) Combined multi-axis robot whose X, Y and Z-axes are 300 mm or shorter and whose rotating part, if

any, has the maximum movement range of within 300 mm

(3) Multi-joint robot whose movable radius and Z-axis are within 300 mm

Among the products featured in our catalogs, the following models are classified as industrial robots:

1. Single-axis ROBO Cylinders RCS2/RCS2CR-SS8 and RCS3/RCS3CR/RCS3P/RCS3PCR whose stroke exceeds 300 mm

2. Single-axis robots The following models whose stroke exceeds 300 mm and whose motor capacity also exceeds 80 W: ISA/ISPA, ISDA/ISPDA, ISWA/ISPWA, IF, FS, NS

3. Linear servo actuators All models whose stroke exceeds 300 mm

4. Cartesian robos Any robot that uses at least one axis corresponding to one of the models specified in 1 to 3

5. IX SCARA robots

All models whose arm length exceeds 300 mm (All models excluding IX-NNN1205/1505/1805/2515, NNW2515 and NNC1205/1505/1805/2515)

including the tip of the rotating part

Pre-3

Notes on Safety of Our Products

Common items you should note when performing each task on any IAI robot are explained below.

No. Task Note

1 Model

selection

2 Transportation

3 Storage/

preservation

4 Installation/

startup

 This product is not planned or designed for uses requiring high degrees of safety.

Accordingly, it cannot be used to sustain or support life and must not be used in the

following applications: [1] Medical devices relating to maintenance, management, etc., of life or health [2] Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities, etc.)

intended to move or transport people [3] Important safety parts in mechanical devices (safety devices, etc.)  Do not use this product in the following environments: [1] Place subject to flammable gases, ignitable objects, flammables, explosives, etc. [2] Place that may be exposed to radiation [3] Place where the surrounding air temperature or relative humidity exceeds the specified

range [4] Place subject to direct sunlight or radiated heat from large heat sources [5] Place subject to sudden temperature shift and condensation [6] Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.) [7] Place subject to excessive dust, salt or iron powder [8] Place where the product receives direct vibration or impact  Do not use this product outside the specified ranges. Doing so may significantly

shorten the life of the product or result in product failure or facility stoppage.

 When transporting the product, exercise due caution not to bump or drop the product.  Use appropriate means for transportation.  Do not step on the package.  Do not place on the package any heavy article that may deform the package.  When using a crane of 1 ton or more in capacity, make sure the crane operators are

qualified to operate cranes and perform slinging work.  When using a crane, etc., never hoist articles exceeding the rated load of the crane,

etc.  Use hoisting equipment suitable for the article to be hoisted. Calculate the load needed

to cut off the hoisting equipment and other loads incidental to equipment operation by

considering a safety factor. Also check the hoisting equipment for damage.

 Do not climb onto the article while it is being hoisted.  Do not keep the article hoisted for an extended period of time.  Do not stand under the hoisted article.

 The storage/preservation environment should conform to the installation environment.

Among others, be careful not to cause condensation. (1) Installing the robot, controller, etc.

 Be sure to firmly secure and affix the product (including its work part).

If the product tips over, drops, malfunctions, etc., damage or injury may result.  Do not step on the product or place any article on top. The product may tip over or the

article may drop, resulting in injury, product damage, loss of/drop in product

performance, shorter life, etc.  If the product is used in any of the following places, provide sufficient shielding

measures: [1] Place subject to electrical noise [2] Place subject to a strong electric or magnetic field [3] Place where power lines or drive lines are wired nearby [4] Place subject to splashed water, oil or chemicals

Pre-4

No. Task Note

4 Installation/

startup

(2) Wiring the cables  Use IAI’s genuine cables to connect the actuator and controller or connect a teaching

tool, etc.  Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place

heavy articles on top. Current leak or poor electrical continuity may occur, resulting in

fire, electric shock or malfunction.

 Wire the product correctly after turning off the power.  When wiring a DC power supply (+24 V), pay attention to the positive and negative

polarities.

Connecting the wires in wrong polarities may result in fire, product failure or

malfunction.  Securely connect the cables and connectors so that they will not be disconnected or

come loose. Failing to do so may result in fire, electric shock or product malfunction.  Do not cut and reconnect the cables of the product to extend or shorten the cables.

Doing so may result in fire or product malfunction. (3) Grounding

 Be sure to provide class D (former class 3) grounding for the controller. Grounding is

required to prevent electric shock and electrostatic charges, improve noise resistance

and suppress unnecessary electromagnetic radiation. (4) Safety measures

 Implement safety measures (such as installing safety fences, etc.) to prevent entry into

the movement range of the robot when the product is moving or can be moved.

Contacting the moving robot may result in death or serious injury.  Be sure to provide an emergency stop circuit so that the product can be stopped

immediately in case of emergency during operation.  Implement safety measures so that the product cannot be started only by turning on the

power. If the product starts suddenly, injury or product damage may result.  Implement safety measures so that the product will not start upon cancellation of an

emergency stop or recovery of power following a power outage. Failure to do so may

result in injury, equipment damage, etc.  Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc.,

during installation, adjustment, etc. If the power is accidently turned on, electric shock

or injury may result.  Implement measures to prevent the work part, etc., from dropping due to a power

outage or emergency stop.  Ensure safety by wearing protective gloves, protective goggles and/or safety shoes, as

necessary.  Do not insert fingers and objects into openings in the product. Doing so may result in

injury, electric shock, product damage, fire, etc.  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged work part,

etc.

5 Teaching

 Whenever possible, perform teaching from outside the safety fences. If teaching must

be performed inside the safety fences, prepare “work rules” and make sure the

operator understands the procedures thoroughly.  When working inside the safety fences, the operator should carry a handy emergency

stop switch so that the operation can be stopped any time when an abnormality occurs.  When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality occurs.

The safety watcher must also make sure the switches are not operated inadvertently by

a third party.  Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.

Pre-5

No. Task Note

5 Teaching  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged load, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

6 Confirmation

operation

 After teaching or programming, carry out step-by-step confirmation operation before

switching to automatic operation.  When carrying out confirmation operation inside the safety fences, follow the specified

work procedure just like during teaching.  When confirming the program operation, use the safety speed. Failure to do so may

result in an unexpected movement due to programming errors, etc., causing injury.  Do not touch the terminal blocks and various setting switches while the power is

supplied. Touching these parts may result in electric shock or malfunction.

7 Automatic

operation

 Before commencing automatic operation, make sure no one is inside the safety fences.  Before commencing automatic operation, make sure all related peripherals are ready to

operate in the auto mode and no abnormalities are displayed or indicated.

 Be sure to start automatic operation from outside the safety fences.  If the product generated abnormal heat, smoke, odor or noise, stop the product

immediately and turn off the power switch. Failure to do so may result in fire or product

damage.  If a power outage occurred, turn off the power switch. Otherwise, the product may

move suddenly when the power is restored, resulting in injury or product damage.

8 Maintenance/

inspection

 Whenever possible, work from outside the safety fences. If work must be performed

inside the safety fences, prepare “work rules” and make sure the operator understands

the procedures thoroughly.

 When working inside the safety fences, turn off the power switch, as a rule.  When working inside the safety fences, the operator should carry a handy emergency

stop switch so that the operation can be stopped any time when an abnormality occurs.  When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality occurs.

The safety watcher must also make sure the switches are not operated inadvertently by

a third party.

 Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.  Use appropriate grease for the guides and ball screws by checking the operation

manual for each model.  Do not perform a withstand voltage test. Conducting this test may result in product

damage.  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged work part,

etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

9 Modification  The customer must not modify or disassemble/assemble the product or use

maintenance parts not specified in the manual without first consulting IAI.  Any damage or loss resulting from the above actions will be excluded from the scope of

warranty.

10 Disposal  When the product becomes no longer usable or necessary, dispose of it properly as an

industrial waste.  When disposing of the product, do not throw it into fire. The product may explode or

generate toxic gases.

Pre-6

Indication of Cautionary Information

The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and “Note,” as specified below.

Level Degree of danger/loss Symbol

Danger

Warning

Caution

Note

Failure to observe the instruction will result in an imminent danger leading to death or serious injury.

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

Warning

Caution

Note

Pre-7

Pre-8

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.

1.2 Meaning of the Model Name

<Type> Slider type

・SA6 ・SA7

Rod type

・RA54 ・RA64 ・RA54GS ・RA64GS ・RA54GD ・RA64GD

<Encoder type> I: Incremental

<Motor type> PM: Pulse motor

ERC-RA54-I-PM-12-300-S-NM

<Options> Blank: No option B: With brake NM: Reversed-home specification FT: Foot bracket (Specified only for rod

types.)

EN: CE-compliant NPN specification

(Sink type)

EP: CE-compliant PNP specification

(Source type)

<Relay cable length> Blank: No cable P: 1 m S: 3 m M: 5 m X: Length specification (Example) X08 = 8 m R: Robot cable specification W: Connectors on both ends RW: Robot cable / Connectors on both ends

<Stroke> 50 to 600 mm (Standard lengths are multiples of 50 mm.) (Example) 100 = 100 mm

<Ball screw lead> 16: 16 mm 12: 12 mm 8: 8 mm 6: 6 mm 4: 4 mm 3: 3 mm

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

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)

Speed (mm/sec)

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)

Speed (mm/sec)

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).

1.3.3 Sound Pressure Levels of This Product Will Not Exceed 70 dB.

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.

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.

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.

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 treatment

[2]

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.

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.)

or larger.

Other

equipment

(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.

[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

 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.

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.

Surge absorber

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.

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.

1. Do not let the cable flex at a single point.

Steel band (piano wire)

Bundle loosely.

2. Do not let the cable bend, kink or twist.

4. Do not let the cable receive a turning force at a

single point.

Do not pinch, drop a heavy object onto or cut the

cable.

Use a curly

cable.

3. Do not pull the cable with a strong force.

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.

7. Notes on use of cable tracks

 The supplied cable is not a robot cable. Accordingly,

never store this cable in a cable track.

 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).

For the extension cable, be sure to use a robot cable.

Use a cable track at a bending radius r of at least 50 mm.

Bending radius

 Do not cause the cables to occupy more than 60%

of the space in the cable bearer.

 Do not store signal lines and power lines for strong

electrical circuits in the same duct.

Cable

Cable bearer

Power line

Signal lines (flat cable, etc.)

Duct

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)

Non-motor end

Top

Bottom

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

Motor cover

LED

Rear bracket

Motor bracket

Motor cover

Rear cover

Cable

Rear cover

Motor end

Cable

2.1.3 (1) Rod Type with a Single Guide (RA54GS/RA64GS)

Right

Coupling bolt

LED

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.)

Motor cover

2.1.3 (2) Rod Type with Double Guides (RA54GD/RA64GD)

Mounting bracket

Non-motor end

Guide bracket

Rod

Top Bottom

Guide bearing

Right

Left

Frame

Guide rod

Coupling bolt

LED

Rear bracket

Motor bracket

Connection port for teaching pendant or PC (The arrow on the connector should face down.)

Rear cover

Motor cover

Motor end

Cable

Motor end

Rear cover

Cable

2.2 Installation

2.2.1 Slider Type

 Installing the actuator

The actuator-mounting surface must be a machined surface or have an equivalent flatness.

The side and bottom faces of the actuator base are parallel with the guides. If high slide accuracy is required, install the actuator by using these surfaces as references.

(Note) Reduced flatness due to installation of an overhung load will cause the base to deform and inhibit

smooth movement of the slider. If the slider movement becomes heavier on the motor end or the slider begins generating noise, correct the flatness. Otherwise, the slider mechanism may end its life prematurely.

Slider type

Install the actuator in the mounting holes provided in the base. Secure the actuator in place using M4 hex cap bolts.

2.2.2 Rod Type

A rod-type actuator can be installed in the following two ways:

 Affixing with a flange

Install the actuator by tightening from the motor end side with hex cap bolts using the holes provided in the flange.

Caution: If the actuator is installed horizontally, exercise

caution not to let the actuator receive excessive forces.

Hex cap bolt

Hole in flange

Flange tightening bolts

Model Nominal thread size Tightening torque

 Affixing through holes in a flange

Hex cap bolt

RA54 M5 3.4 Nm (0.35 kgfm)

RA64 M6 5.4 Nm (0.55 kgfm)

Caution: If the actuator is installed horizontally,

exercise caution not to let the actuator receive excessive forces.

Flange tightening bolts

Model Nominal thread size Tightening torque

RA54GD M5

RA64GD

Steel bolt-bearing surface: 7.3 N•m Aluminum bolt-bearing surface: 3.4 N•m

Steel bolt-bearing surface: 12.3 N•m Aluminum bolt-bearing surface: 5.4 N•m

 Affixing with foot brackets (optional)

If optional foot brackets are used, install the foot brackets using hex cap bolts.

Foot-bracket tightening bolts

Model Nominal thread size Tightening torque

RA54

RA54GS

M6 5.4 Nm (0.55 kgfm)

RA54GD

RA64

RA64GS

M8 11.5 Nm (1.17 kgfm)

RA64GD

2.2.3 Installing the Load

 Slider Type

Four tapped holes are provided in the slider, so affix the load using these holes (indicated by arrows in the figure shown to the left).

Type Slider mounting hole

SA6, SA7 M5, depth 9 mm

Nominal thread size Tightening torque

Bolt bearing surface: steel Bolt bearing surface: aluminum

M5 7.3 Nm (0.74 kgfm) 3.4 Nm (0.35 kgfm)

The affixing method of the load shall conform to the installation method of the actuator.

In an application where the actuator is moved with the slider fixed, install the load using the tapped holes in the slider in the same manner.

The slider has two reamed holes. Use these holes when high repeatability is required for load installation/removal. When fine-tuning the squareness of the load, etc., make adjustment by using one of these two reamed holes in the slider.

Type Reamed hole

SA6, SA7

5, H10, depth 10 mm

 Rod Type

A bolt is attached on the rod end bracket, so use this bolt to affix the load. (Use the supplied nut, if necessary.)

Rod end bracket

Model Rod end bracket

RA54 M8, length 18 mm RA64 M10, length 21 mm

Note) Apply a spanner at the rod end bracket to prevent

the rod from receiving any rotating moment when the load is installed.

Applying excessive rotating moment to the rod may

damage the rod. RA54: Width across flats 13 mm RA64: Width across flats 17 mm

 Rod type with a guide(s)

Tapped holes are provided in the guide bracket. Affix the work using these holes (shown by the arrows in the figures at left).

Model Nominal thread size

RA54GS M5

Single guide

RA54GD

RA64GS M6

RA64GD M6

Nominal

thread size

Bolt bearing surface: steel Bolt bearing surface: aluminum

Tightening torque

M5 7.3 Nm (0.74 kgfm) 3.4 Nm (0.35 kgfm)

Double guides

12.3 Nm (1.26 kgfm) 5.4 Nm (0.55 kgfm)



3. Wiring

3.1 Basic Structure

Host system <PLC>

ERC actuator

Teaching pendant

<RCA-T>

Optional

Cable length: 5 m

Relay cable

Standard cable <CB-ERC-PWBIO * * *> Robot cable <CB-ERC-PWBIO * * *-RB>

Cable length: 1 m, 3 m, 5 m

PIO

24-VDC control/motor power supply (2 A or more) Brake release switch Emergency-stop/motor-power cutoff circuit Drain wire

SIO 

PC software

<RCB-101-MW>

Optional

PERSONAL

COMPUTER

(Not used)

 Connection diagram

[1] When the control board is of the NPN specification [sink type]

Input power supply

(2 A or more)

24V

EMG signal

Brake release switch

60 mA ma

(Note)

*Light blue (Red 1)

*Light blue (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

White (Red 1)

White (Black 1)

CN1

2A EMS1

2B EMS2

4A MPI

4B GND

5A MPI

5B GND

3A 24V

3B BKR

Host system

<PLC>

side

Output

side

Input

(Not used)

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

*Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

Orange (Red 1)

Orange (Black 1)

CN2

10A

10B

1A SGA Serial communication

1B SGB

Drain wire

* In the case of a robot cable, the wire colors change as follows.

Wire color Pin number Gray (Red 1) 2A Gray (Black 1) 2B Gray (Red 2) 7A Gray (Black 2) 7B

(Note) To release the brake, connect a switch between BKR and 0 V and turn on the switch.

ERC actuator

Contact output for EMG switch on teaching pendant

Motor drive power supply

Control power supply

OFF when the brake is controlled by the controller, or ON when the brake is released (Applicable to an actuator with brake)

I/O interface (Refer to the I/O connections for each PIO pattern)

[2] When the control board is of the PNP specification [source type]

ERC actuator

Input power supply

(2 A or more)

24V

EMG signal

Brake release switch

Host system

<PLC>

(Note)

Output

Input

60 mA ma

side

*Light blue (Red 1)

*Light blue (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

White (Red 1)

White (Black 1)

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

*Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

CN1

2A EMS1

2B EMS2

4A MPI

4B GND

5A MPI

5B GND

3A 24V

3B BKR

10A

10B

Contact output for EMG switch on teaching pendant

Motor drive power supply

Control power supply

OFF when the brake is controlled by the controller, or ON when the brake is released (Applicable to an actuator with brake)

I/O interface (Refer to the I/O connections for each PIO pattern)

(Not used)

Orange (Red 1)

Orange (Black 1)

CN2

1A SGA Serial communication

1B SGB

Drain wire

* In the case of a robot cable, the wire colors change as follows.

Wire color Pin number Gray (Red 1) 2A Gray (Black 1) 2B Gray (Red 2) 7A Gray (Black 2) 7B

(Note) To release the brake, connect a switch between BKR and 24 V and turn on the switch.

3.2 I/O Connections for PIO Pattern 1 [3 Points] (Air Cylinder)

The following description assumes that the ERC is used in the place of an air cylinder. The number of positioning points is limited to three, but a direct command input and a position complete output are provided separately for the target position in line with the conventional practice of air cylinder control.

Note: The factory setting is “8 points,” so set parameter No. 25 to “1.” The pause signal can be

disabled in parameter No. 15.

Host system <PLC>

Rear end move

Front end move

Output

Intermediate point move

side

Pause

Rear end complete

Input

Front end complete

side

Intermediate point complete

Alarm

3.2.1 Explanation of I/O Signals

Category Signal name

Rear end move ST0 The actuator starts moving to the rear end at the rise edge of the signal.

Signal

abbreviation

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

*Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

ERC actuator end

CN1 (Signal abbreviation)

6A ST0

6B ST1

* Robot cable

7A ST2

Gray (Red 2)

Gray (Black 2)

8B *STP

9A PE0

9B PE1

10A PE2

10B *ALM

(Note) *STP and *ALM are always ON.

Function overview

Input

Output

Front end move ST1 The actuator starts moving to the front end at the rise edge of the signal.

Intermediate point

move

*Pause *STP ON: The actuator can be moved, OFF: The actuator decelerates to a stop

Rear end complete

Front end

complete

Intermediate point

complete

*Alarm *ALM

ST2

PE0 The signal turns ON when the actuator completes moving to the rear end.

PE1 The signal turns ON when the actuator completes moving to the front end.

PE2

The actuator starts moving to the intermediate point at the rise edge of the signal.

The signal turns ON when the actuator completes moving to the intermediate point.

This signal remains ON while the controller is operating properly, and turns OFF when an alarm generates. The *ALM signal is synchronized with the green/red indication of the LED.

(Note) The signal remains ON while the motor drive power is cut off.

3.2.2 Details of Input Signals

The input signals from this controller have an input time constant, in order to prevent malfunction caused by chattering, noise, etc. Each input signal will switch the applicable setting when received continuously for 6 msec or more. In other words, when a given input is switched from OFF to ON, the controller will recognize the ON state of the signal only after elapse of 6 msec. The same applies to the switching of an input from ON to OFF. (Fig. 1)

Recognition by the controller

 Movement to each position (ST0 to ST2)

When the OFF  ON rise edge of each movement signal is detected, the actuator will move to the target position corresponding to the applicable position data. Before executing a command using any of these signals, make sure the target position, speed and other operation data are set in the position table using a PC or teaching pendant.

Rear end move (ST0) 0 Set the rear end position in position No. 0.

Input signal

Not recognized Not recognized

6 [msec] 6 [msec]

Fig. 1 Recognition of Input Signal

Corresponding

position number

Remarks

Front end move (ST1) 1 Set the front end position in position No. 1.

Intermediate point 1 move (ST2) 2 Set the intermediate point in position No. 2.

If a movement command is issued when the first home return is not yet completed after the power was input, home return will be performed automatically to establish the coordinates first, after which the actuator will move to the target position.

 Pause (*STP)

When this signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. The remaining movement is retained and will be resumed when the signal is turned ON again. The *STP signal can be used for the following purposes: [1] Provide a low-level safety measure to stop the axis while the servo is ON, such as a sensor that detects a

person approaching the system [2] Prevent contact with other equipment [3] Perform positioning based on sensor or LS detection (Note) If the *STP signal is input while the actuator is performing home return, the movement command will

be retained if the actuator is yet to contact a mechanical end. If the signal is input after the actuator has reversed upon contacting a mechanical end, home return will be performed again from the beginning.

3.2.3 Details of Output Signals

 Completion of each position (PE0 to PE2)

These signals indicate that the target position corresponding to each movement command (ST0, ST1 or ST2) has been reached, in the same way the reed switch signal does for an air cylinder.

Output signal Meaning of the signal

Rear end complete (PE0)

Front end complete (PE1)

Intermediate point

complete (PE2)

(Note) Although these signals remain OFF while the motor drive power is cut off, once the power is

reconnected the signal will return to the ON state if the current actuator position is within the in-position band over the target position. If the actuator is positioned outside the in-position band, the signal will remain OFF.

The actuator has reached and stopped at the rear end (target position set in position No. 0).

The actuator has reached and stopped at the front end (target position set in position No. 1).

The actuator has reached and stopped at the intermediate point (target position set in position No. 2).

 Alarm (*ALM)

This signal remains ON while the controller is operating properly, and turns OFF when an alarm generates. Monitor the OFF state on PLC and provide appropriate safety measures for the entire system. Refer to “9. Troubleshooting” for alarm details.

3.3 I/O Connections for PIO Pattern 0 [8 Points]

Note The factory setting is “8 points.” The pause signal can be disabled in parameter No. 15.

Host system <PLC>

Command position 1

Command position 2

Output

side

Command position 4

Home return

Position complete

Home return completion

Input

side

Zone output

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

*Light blue (Black 2)

Start

Pause

White (Black 2)

Yellow (Black 2)

Alarm

White (Red 2)

Yellow (Red 2)

Pink (Red 2)

Pink (Black 2)

ERC actuator end

CN1 (Signal abbreviation)

6A PC1

6B PC2

7A PC4

* Robot cable Gray (Red 2)

Gray (Black 2)

7B HOME

8A CSTR

8B *STP

9A PEND

9B HEND

10A ZONE

10B *ALM

(Note) *STP and *ALM are always ON.

3.4 I/O Connections for PIO Pattern 2 [16 Points]

Note The factory setting is “8 points,” so set parameter No. 25 to “2.” The pause signal can be

disabled in parameter No. 15.

Host system <PLC>

Command position 1

Command position 2

Output

Command position 4

side

Command position 8

Position complete

Home return completion

Input

side

Zone output

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

*Light blue (Black 2)

White (Red 2)

Start

White (Black 2)

Pause

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

Alarm

ERC actuator end

CN1 (Signal abbreviation)

6A PC1

6B PC2

7A PC4

* Robot cable Gray (Red 2)

Gray (Black 2)

7B PC8

8A CSTR

8B *STP

9A PEND

9B HEND

10A ZONE

10B *ALM

(Note) *STP and *ALM are always ON.

3.4.1 Explanation of I/O Signals

The following explains the signals used in the “8 points” and “16 points” patterns.

3.5 Configuration Using a SIO Converter

If any of the following conditions applies, use a SIO converter to connect the teaching pendant, PC or PLC’s communication module: [1] The actuator’s rear cover cannot be reached and therefore the teaching pendant or PC cannot be connected. [2] Want to execute movement operation or parameter edit for all axes when multiple axes are connected to the

single equipment.

[3] Want to operate the actuator via serial communication using the PLC’s communication module.

Teaching pendant <RCA-T>

Optional

Cable length: 5 m

ERC actuator

RS232C crossed

cable (provided

by the user)

Host system <PLC>

Relay cable Standard cable <CB-ERC-PWBIO * * *> Robot cable <CB-ERC-PWBIO * * *-RB> Cable length: 1 m, 3 m, 5 m

 PIO

TB2

EMG2

EMG1

24V

SIO converter <RCB-TU-SIO-A> <RCB-TU-SIO-B>

SIO 

24-VDC control/motor power supply (2 A or more) Brake release switch Emergency-stop/motor-power cutoff circuit Drain wire

Note: Do not connect a teaching pendant and a PC at the same time. If both are connected at the

same time, a communication error (message level) will occur.

PC software

<RCB-101-MW>

Optional

PERSONAL

COMPUTER

B A

TB1

 Connection diagram

[1] When the control board is of the NPN specification [sink type]

EMG signal

Input power supply

24V

* In the case of a robot cable, the wire colors change as follows.

Wire color Pin number Gray (Red 1) 2A Gray (Black 1) 2B Gray (Red 2) 7A Gray (Black 2) 7B

(Note) To release the brake, connect a switch between BKR and 0 V and turn on the switch.

SIO converter (RCB-TU-SIO-A/B)

TB2

Brake release switch

side

Output

side

Input

(Not used)

60 mA

Host system

<PLC>

Relay

EMG2

EMG1

24V

TB1

*Light blue (Black 2)

*Light blue (Black 1)

Contact output for EMG switch on teaching pendant

CN1

Orange (Red 1)

Orange (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

White (Red 1)

White (Black 1)

(Note)

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

*Light blue (Red 1)

1A SGA

1B SGB

4A MPI

4B GND

5A MPI

5B GND

3A 24V

3B BKR

10A

10B

2A EMS1

2B EMS2

ERC actuator

Serial communication

Motor drive power supply

Control power supply

I/O interface (Refer to the I/O connections for each PIO pattern)

Drain wire

[2] When the control board is of the PNP specification [source type]

Input power supply

EMG signal

24V

Host system

SIO converter (RCB-TU-SIO-A/B)

TB2

Brake release switch

side

Output

side

Input

(Not used)

60 mA

<PLC>

Relay

EMG2

EMG1

24V

TB1

Orange (Red 1)

Orange (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Black 1)

White (Red 1)

White (Black 1)

(Note)

Orange (Red 2)

Orange (Black 2)

*Light blue (Red 2)

*Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

*Light blue (Red 1)

*Light blue (Black 1)

Contact output for EMG switch on teaching pendant

ERC actuator

CN1

1A SGA

1B SGB

4A MPI

Pink (Red 1)

4B GND

5A MPI

5B GND

3A 24V

3B BKR

I/O interface (Refer to the I/O connections for

each PIO pattern)

10A

10B

2A EMS1

2B EMS2

Serial communication

Motor drive power supply

Control power supply

Drain wire

* In the case of a robot cable, the wire colors change as follows.

Wire color Pin number Gray (Red 1) 2A Gray (Black 1) 2B Gray (Red 2) 7A Gray (Black 2) 7B

(Note) To release the brake, connect a switch between BKR and 24 V and turn on the switch.

3.6 Configuration Using an Insulated PIO Terminal Block

If either of the following conditions applies, use an insulated PIO terminal block: [1] Want to insulate the control power supply from the PIO power supply. [2] Want to change the I/O logic of the control board

ERC actuator

Relay cable Standard cable <CB-ERC-PWBIO * * *-H6> Robot cable <CB-ERC-PWBIO * * *-RB-H6> Cable length: 1 m, 3 m, 5 m

Connector

TB2

Insulated PIO terminal block NPN, vertical <RCB-TU-PIO-A> NPN, horizontal <RCB-TU-PIO-B> PNP, vertical <RCB-TU-PIO-AP> PNP, horizontal <RCB-TU-PIO-BP>

Teaching pendant <RCA-T>

Optional

Cable length: 5 m

TB4

PC software

<RCB-101-MW>

Optional

PERSONAL

COMPUTER

24-VDC control/motor power supply (2 A or more) Brake release switch Emergency-stop/motor-power cutoff circuit

TB1

TB3

Host system <PLC>

 Connection diagram

[1] When the control board is of the NPN specification [sink type]

EMG signal

Input power supply

24V

Relay

60 mA Max

Brake release switch

Host system

<PLC>

Input

common

side

Output

side

Input

Output

common

[1] Insulate the power

supply

Input common 24 V 0 V

Output common 0 V 24 V

(Note) To release the brake, connect a switch between the TB1-BK terminal and 0 V and turn on the switch.

Insulated PIO terminal block (RCB-TU-PIO-A/B)

TB1

Contact output for EMG switch on teaching pendant

Motor drive power supply

Control power supply

I/O interface

(Refer to 4.4, “Insulated PIO Terminal Block.”)

(Note)

EMS2

EMS1

24V

TB4

TB3

[2] Change to PNP

TB2

(Not used)

Connect to FG

Relay cable

[2] When the control board is of the PNP specification [source type]

Insulated PIO terminal block (RCB-TU-PIO-AP/BP)

EMG signal

TB1

TB2

(Not used)

Contact output for EMG switch

TB4

EMS2

on teaching pendant

EMS1

Motor drive power supply

Control power supply

24V

Connect to FG

Input power supply

24V

Relay

60 mA Max

Brake release switch

(Note)

Host system

<PLC>

Input

common

side

Output

side

Input

Output

common

TB3

I/O interface

(Refer to 4.4, “Insulated PIO

Terminal Block.”)

Relay cable

[1] Insulate the power

supply

[2] Change to NPN

Input common 0 V 24 V

Output common 24 V 0 V

(Note) To release the brake, connect a switch between the TB1-BK terminal and 24 V and turn on the switch.

3.7 Configuration Using Both SIO Converter and Insulated PIO Terminal Block

Teaching pendant <RCA-T>

Optional

Cable length: 5 m

ERC actuator

Relay cable Standard cable <CB-ERC-PWBIO * * *-H6> Robot cable <CB-ERC-PWBIO * * *-RB-H6> Cable length: 1 m, 3 m, 5 m

TB2

24-VDC control power suppl

(Emergency-stop circuit)

EMG2

EMG1

24V

SIO converte

24-VDC control/motor power supply (2 A or more) Brake release switch Motor-power cutoff circuit

TB4

Connector

TB2

A B

Insulated PIO terminal block

Note: Do not connect a teaching pendant and a PC at the same time. If both are connected at the

same time, a communication error (message level) will occur.

PC software

<RCB-101-MW>

Optional

PERSONAL

COMPUTER

RS232C crossed cable (provided by the user)

NPN, vertical <RCB-TU-PIO-A>

TB1

NPN, horizontal <RCB-TU-PIO-B> PNP, vertical <RCB-TU-PIO-AP> PNP, horizontal <RCB-TU-PIO-BP>

Host system <PLC>

TB3

SIO converter Vertical <RCB-TU-SIO-A> Horizontal <RCB-TU-SIO-B>

TB1

Insulated PIO terminal block

 Connection diagram

[1] When the control board is of the NPN specification [sink type]

EMG signal

Relay

60 mA Max

(Not used)

Input power supply

24V

Brake release switch

(Note)

Host system

<PLC>

Input

common

side

Output

side

Input

Output

common

[1] Insulate the power supply [2] Change to PNP

Input common 24 V 0 V

Output common 0 V 24 V

(Note) To release the brake, connect a switch between the TB1-BK terminal and 0 V and turn on the switch.

SIO converter (RCB-TU-SIO-A/B)

TB2

EMG2

EMG1

24V

Insulated PIO terminal block (RCB-TU-PIO-A/B)

TB1

TB4

TB3

Contact output for EMG switch on teaching pendant

EMS2

EMS1

Motor drive power supply

24V

Control

I/O interface

(Refer to 4.4, “Insulated PIO

Terminal Block.”)

TB2

ower suppl

Twisted pair

Connect to FG

Relay cable

[2] When the control board is of the PNP specification [source type]

EMG signal

60 mA Max

Relay

SIO converter (RCB-TU-SIO-A/B)

TB2

Contact output for EMG

EMG2

switch on teaching pendant

EMG1

24V

Insulated PIO terminal block (RCB-TU-PIO-AP/BP)

Input power supply

24V

(Not used)

Brake release switch

(Note)

TB1

TB4

EMS2

EMS1

Motor drive power supply

24V

Control

ower suppl

Host system

<PLC>

Input

common

side

Output

Input

Output

common

side

TB3

I/O interface

(Refer to 4.4, “Insulated PIO

Terminal Block.”)

TB1

Twisted pair

TB2

Connect to FG

Relay cable

[1] Insulate the power supply [2] Change to NPN

Input common 0 V 24 V

(Note) To release the brake, connect a switch between the TB1-BK terminal and 24 V and turn on the switch.

Output common 24 V 0 V

3.8 Controlling Multiple Axes via Serial Communication

The following operations become possible if multiple axes are controlled: [1] Executing movement operations or parameter edit to all axes by connecting teaching pendant or PC via

SIO converter.

[2] Performing operations via serial communication with the PLC’s communication module as a host by way of

a SIO converter.

3.8.1 Basic Specifications

Specification item Description

Communication format RS485

Transmission speed

Maximum number of units that can be connected

Maximum cable length 100 m or less

Terminal resistor

(9600 bps, 19200 bps or 38400 bps may also be selected)

120  (built into the SIO converter/insulated PIO terminal block);

required if the cable length is 10 m or more.

115200 bps

16 axes

3.8.2 Address Assignment

In a linked configuration where multiple axes are connected via serial communication, the host (teaching pendant, PC or communication module) assigns an address to each axis in order to recognize the corresponding actuator. Assign addresses in the setting screen of the teaching pendant or PC.  Overview of operation on the PC

[1] Open the main window  [2] Click Setup (S)  [3] Bring the cursor to Controller Setup (C)  [4] Bring

the cursor to Assign Address (N) and click the mouse  [5] Enter an appropriate number in the

address table.

 Overview of operation on the teaching pendant RCA-T

[1] Open the User Adjustment screen  [2] Use the  key to bring the cursor to Address No.  [3] Enter

an appropriate address and press the ENTER key  [4] Enter “2” under Adjust m ent No. and press the

ENTER key  [5] Restart the actuator.

 Overview of operation on the simple teaching pendant RCA-E

[1] Open the User Adjustment screen  [2] Press the ENTER key to open the screen showing Address No.

 [3] Enter an appropriate address and press the ENTER key  [4] Enter “2” under Adjus t ment No.

and press the ENTER key  [5] Restart the actuator.

 Overview of operation on the jog teacher RCB-J

[1] Press the ON/OFF and RUN keys together to turn on the power  [2] Press the – key to open the

screen showing Axis No.  [3] Use the + and – keys to set an appropriate address  [4] Press the SET

key  [5] Restart the actuator.

Refer to the operation manual for the teaching pendant or PC software for the specific operating procedure.

In the actual process of assigning addresses, the teaching pendant or PC and the target actuator must have a one-on-one link. Therefore, disconnect the communication cables (SGA/SGB) from other axes to tentatively provide a condition where not more than one axis is connected.

3.8.3 Wiring Examples for Linking Multiple Axes

 Using only a SIO converter

(The same wiring applies to a configuration for automatic operation via serial communication.)

Teaching pendant PC PLC’s communication module

One-pair shielded cable

(with built-in terminal resistor)

SIO converter

TB1

(Note 1) If a communication error occurs when the overall length of communication cable is 10 m or

more, connect a SIO converter to the last axis. (Note 2) If the actuators use different power supplies, align 0 [V] on all power supplies. (Note 3) Connect the shielded wire of each axis to FG. (Note 4) If the overall length of link cable exceeds 30 m, use wire of 22AWG or larger size.

SIO converter

TB1

Relay terminal block

SGA

SGB

Actuator 1

Actuator 2

Actuator 3

Actuator 16

 Using both SIO converter and insulated PIO terminal block

(Communication with the PLC is performed via parallel I/O connection.)

One-pair shielded cable

(Note 1) Only on the last axis set the terminal-resistor connection switch to the [RTON] side. (Note 2) If the actuators use different power supplies, align 0 [V] on all power supplies. (Note 3) Connect the shielded wire of each axis to FG. (Note 4) If the overall length of link cable exceeds 30 m, use wire of 22AWG or larger size.

Teaching pendant PC PLC’s communication module

SIO converter

TB1

Insulated PIO terminal block

TB2

Actuator 1

Actuator 2

Actuator 3

Actuator 16

(

)

3.9 Emergency-Stop Circuit

Examples of internal circuit and recommended circuit are shown below.

For auxiliary relays, use relays with a diode for absorbing coil surge.

24V

External EMG

reset switch

External

EMG switch

EMS1

ERC

Relay

EMS2

60 mA MAX)

24V

Motor drive source

MPI

Connection detection

relay

(Rush current: 6 A / Rated current: 2 A

MPI

GND

Motor power supply

Controller power supply

[Reference] Recommended relays are listed below. Use this information as a reference when selecting a relay.

Manufacturer Product name

Omron LY Series

Panasonic HC Relay Series

For the detailed specifications of each product, check the specification sheet issued by the manufacturer.

Teaching pendant

EMG

switch

Power supply

 Example of multi-axes circuit allowing each axis to be connected/disconnected to the teaching

pendant

24V

External EMG

reset switch

External

EMG switch

Relay

MC M1 M2 M3

Actuator 1

Teaching pendant

EMG switch

EMS1 EMS2

Actuator 2

Teaching pendant

EMG switch

EMS1 EMS2

Actuator 3

Teaching pendant

EMG switch

EMS1 EMS2

Actuator 1

MP1 GND

Actuator 2

MP1 GND

Actuator 3

MP1 GND

3.10 Relay Cable

 No connector on the counter-actuator end (When connecting the actuator directly to a host system)

(J.S.T. Mfg.)

V0.5 - 3

Orange (Red 1)

Orange (Black 1)

Housing: XMP-02V (J.S.T. Mfg.) Socket contact: SXA-001T-P0.6

(Supplied cables to be connected to CN2)

(Note) Connecting 24V to the SGA/SGB serial-communication lines will cause a breakdown.

CN2

CB-ERC-PWBIO * * * (Standard cable) CB-ERC-PWBIO * * *-RB (Robot cable)

Actuator end

CN1

1 9 8 7 6 5 4 3 2 1

D-2100

AMP

B A

100

CN1

Standard cable Robot cable

Orange (Red 1)

Orange (Black 1)

Light blue (Red 1) Light blue (Black 1)

White (Red 1)

White (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

Orange (Red 2)

Orange (Black 2)

Light blue (Red 2) Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

Wire colo

Orange (Red 1)

Orange (Black 1)

Gray (Red 1) Gray (Black 1)

White (Red 1)

White (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

Orange (Red 2)

Orange (Black 2)

Gray (Red 2) Gray (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

Wire color

CN2

Signal

name

SGA

name

Drain wire

Pin name

1A 1B

2A 2B

3B 4A 4B 5A 5B

6A 6B

7A 7B

8A 8B 9A

9B 10A 10B

Housing: 1-1318115-9 (AMP) Tab contact: 1318112-1

Shielded wire

Connector on CN2 end

J.S.T. Mfg. V 0.5 - 3

Wire color Signal name Pin name

Black SGB 2

100

Housing: XMR-02V (J.S.T. Mfg.) Pin contact: SXM-001T-P0.6

Red SGA 1

To prevent miswiring, a two-pin connector is installed at the ends of the applicable lines. If multiple axes are linked, connect these supplied cables to the CN2 connector and extend as required, or cut them off at the base of the CN2 connector and install crimp terminals directly.

(

)

 Connectors on both ends (When using an insulated PIO terminal block)

Housing: 1-1318118-9 (AMP) Receptacle contact: 1318108-1

A B

(J.S.T. Mfg.)

V0.5 - 3

CN2

Wire color

Orange (Red 1)

Orange (Black 1)

Light blue (Red 1)

Light blue (Black 1)

White (Red 1)

White (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

Orange (Red 2)

Orange (Black 2)

Light blue (Red 2)

Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

Pin name

Terminal-block end

CN2

10A

10B

Drain wire

CB-ERC-PWBIO * * *-H6 (Standard cable) CB-ERC-PWBIO * * *-RB-H6

Robot cable

Shielded wire

Actuator end

9 8 7 6 5

3 2 1

Pin name

Orange (Red 1)

Orange (Black 1)

Light blue (Red 1) Light blue (Black 1)

White (Red 1)

White (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

Orange (Red 2)

Orange (Black 2)

Light blue (Red 2) Light blue (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

10A

Pink (Red 2)

10B

Pink (Black 2)

Housing: 1-1318115-9 (AMP) Tab contact: 1318112-1

CN1

0-2100

AMP

CN1

Wire color

Standard cable Robot cable

Orange (Red 1)

Orange (Black 1)

Gray (Red 1) Gray (Black 1)

White (Red 1)

White (Black 1)

Yellow (Red 1)

Yellow (Black 1)

Pink (Red 1)

Pink (Black 1)

Orange (Red 2)

Orange (Black 2)

Gray (Red 2) Gray (Black 2)

White (Red 2)

White (Black 2)

Yellow (Red 2)

Yellow (Black 2)

Pink (Red 2)

Pink (Black 2)

4. Electrical Specifications

4.1 Controller

Specification item Description

Number of controlled axes 1 axis/unit

Supply voltage

Supply current 2 A max.

Control method Weak field-magnet vector control (patent pending)

Positioning command Position number specification

Position number Maximum 16 points

Backup memory

PIO 6 dedicated inputs/4 dedicated outputs

LED indicator Servo ON (green)/Alarm (red)

Communication RS485 1 channel (terminated externally)

Electromagnetic brake Release

Relay cable length 10 m or less

Insulation strength

Environment Operating temperature

Operating humidity 85%RH or less (non-condensing)

24 VDC 10%

Position number data and parameters are saved in nonvolatile memory. Serial EEPROM can be rewritten 100,000 times.

The user must provide a selector switch. (Current consumption:

0.15A max.)

500 VDC, 10 M

0 to 40C

Operating environment No contact with corrosive gases.

Storage temperature

Storage humidity 90%RH or less (non-condensing)

Vibration resistance

Protection class IP20

Weight Approx. 32 g

External dimensions 109 W x 40 D (mm), printed circuit board

-10 to 65C

10 to 57 Hz in XYZ directions / Pulsating amplitude: 0.035 mm (continuous), 0.075 mm (intermittent)



4.2 I/O Signal Interface Circuit

4.2.1 External Input Specifications

Item Specification

Number of input points 6 points

Input voltage

Input current 4 mA/point

Leak current 1 mA/point or less

Operating voltage

[NPN specification]

External power supply 24 VDC

[PNP specification]

External power supply 24 VDC

24 VDC  10%

ON voltage: 18 V min. (3.5 mA) OFF voltage: 6 V max. (1 mA)

CN1

Each input

4B, 5B

CN1

Each input

4B, 5B

GND

FUSE

5.6 K

FUSE

5.6 K

ERC

Power supply (VP24)

Internal circuit

GND

ERC

Power supply (VP24)

Internal circuit

GND



4.2.2 External Output Specifications

Item Specification

Number of output points 4 points

Rated load voltage 24 VDC

Maximum current 60 mA/point

Residual voltage 2 V or less

Shorting/reverse-voltage protection

[NPN specification]

ERC

Power supply (VP24)

4 output points

Internal circuit

[PNP specification]

Power supply (VP24)

ERC

FUSE

4 output points

Internal circuit

GND

Fusing resistor (27 , 0.1 W)

FUSE

Fusing resistor 27  0.1 W

Power MOS FET

GND

Power MOS FET

Fusing resistor

GND

0.1 W

CN1 3A

Each output

4B, 5B

CN1 3A

Each output

4B, 5B

Load

External power supply 24 VDC

Load

GND

4.3 SIO Converter (Optional)

Model: RCB-TU-SIO-A (Vertical installation) RCB-TU-SIO-B (Horizontal installation)

This unit is required if any of the following conditions applies: [1] The actuator’s rear cover cannot be reached and therefore the teaching pendant or PC cannot be

connected.

[2] Want to execute movement operation or parameter edit for all axes when multiple axes are connected to

the single equipment.

[3] Want to operate the actuator via serial communication using the PLC’s communication module.

 Explanation of functions

[2] Link-connection

terminal block (TB1)

TB1

[6] Monitor LEDs

A B

LED1 LED2

RS232

[3] D-sub, 9-pin connector

[1] Power/emergency-stop terminal block (TB2)

EMG1, EMG2

24V

Provide a contact output for the emergency-stop switch on the teaching pendant (RCA-T/E). EMG1 and EMG2 connect to the emergency-stop switch on the teaching pendant when the PORT switch is ON, or are shorted when the PORT switch is OFF. These terminals comprise an interlock with a safety circuit provided by the user.

Positive side of the 24-V power supply

Power supply for the teaching pendant and conversion circuit Current consumption: 0.1 A max.

Negative side of the 24-V power supply

FG of the 24-V power supply

[2] Link-connection terminal block (TB1)

A connection port for linking the controller. “A” on the left side connects to SGA (wire color: orange/red 1) in the relay cable or “A” on the insulated PIO terminal block TB2. “B” on the right side connects to SGB (wire color: orange/black 1) in the relay cable or “B” on the insulated PIO terminal block TB2. (Note) Be sure to use twisted pair wires for the above two lines (SGA/SGB).

[3] D-sub, 9-pin connector

A connection port with the host PC or PLC’s communication module.

[4] Mini DIN, 8-pin connector

A connection port with the teaching pendant.

[1] Power/emergency-stop

terminal block (TB2)

24V

EMG2

EMG1

TB2

PORT

SW1

[5] PORT switch

[4] Mini DIN, 8-pin connector

[5] PORT switch

A switch for enabling/disabling the teaching pendant. Set the switch to ON when a teaching pendant is used, or OFF when teaching pendant is not used.

[6] Monitor LEDs

LED1 --- Lit when the controller is transmitting LED2 --- Lit when the RS232 is transmitting

(Reference) Connection drawing of a RS232C crossed cable

SIO converter end PC end

D-sub 9-pin, female

Signal No

1 RD 2 SD 3 ER 4 SG 5 DR 6

RS 7 CS 8 9

No Signal 1 2 RXD 3 TXD 4 DTR 5 SG 6 DSR 7 RTS 8 CTS 9

D-sub 9-pin, female

(

)

(

)

4.4 Insulated PIO Terminal Block (Optional)

Model: RCB-TU-PIO-A (Combined with a NPN control board: Vertical installation) RCB-TU-PIO-B (Combined with a NPN control board: Horizontal installation) RCB-TU-PIO-AP (Combined with a PNP control board: Vertical installation) RCB-TU-PIO-BP (Combined with a PNP control board: Horizontal installation)

This unit is required if either of the following conditions applies: [1] Want to insulate the control power supply from the PIO power supply. [2] Want to change the I/O logic of the control board.

 Control board: NPN (sink type)  Host system: PNP (source type)  Control board: PNP (source type)  Host system: NPN (sink type)

 Explanation of functions

[External view of RCB-TU-PIO-A/B]

[4] Relay

connector (J1)

A B

[2] Link-connection

[External view of RCB-TU-PIO-AP/BP]

[4] Relay

connector (J1)

A B

[2] Link-connection

[3] Ground terminal

RTON

[5] Terminal-resistor connection switch

terminal block

[3] Ground terminal

block (TB4)

RTON

[5] Terminal-resistor connection switch

terminal block

block (TB4)

1 2 3 4 5 6 7 8 9 10 11 12

TB2

FG 0V

1 2 3 4 5 6 7 8 9 10 11 12

TB2

24V

EMS1

EMS2

[1] Power/emergency-stop

terminal block (TB1)

[6] PIO-connection

terminal block (TB3)

EMS2

[1] Power/emergency-stop

terminal block (TB1)

[6] PIO-connection

terminal block (TB3)

[1] Power/emergency-stop terminal block (TB1)

EMS1, EMS2

BK MP

24V 0V

Provide a contact output for the emergency-stop switch on the teaching pendant (RCA-T/E). EMS1 and EMS2 are provided to comprise an interlock with a safety circuit provided by the user when a teaching pendant with emergency-stop switch is connected to the connector on the rear cover.

Connection port for the brake release switch Motor power supply port Positive side of the 24-V control power supply Negative side of the 24-V control power supply

[2] Link-connection terminal block (TB2)

A connection port for linking a SIO converter, if used. “A” on the left side connects to link-connection terminal block (A) on the SIO converter. “B” on the right side connects to link-connection terminal block (B) on the SIO converter. (Note) Be sure to use twisted pair wires for the above two lines (SGA/SGB).

[3] Frame-ground/ground terminal block (TB4)

 Frame-ground terminal (FG) . . . (1) A connection port for the relay cable’s shielded wire (drain wire). (2) A connection port for the ground wire leading to the enclosure.  Ground terminal (0 V) . . . Use this terminal as a relay port to connect a different power-supply line to the same

grounding point.

[4] Relay connector (J1)

A connector port for the relay cable (CB-ERC-PWBIO-***-H6).

[5] Terminal-resistor connection switch

If a SIO converter is used and the link cable is long (10 m or more, as a guideline), a terminal resistor will be required to prevent signal reflection. This unit can be used in the above application, because the TB2 terminal block has a built-in terminal resistor. Setting the switch to the [RTON] side will connect the terminal resistor of approx. 120 .

[6] PIO connection terminal block (TB3)

A PLC connection port. Detailed signal specifications are shown below.

[1] RCB-TU-PIO-A/B (When the control board is of the NPN specification)

TB3

0 (8-point type) 1 (3-point type) 2 (16-point type)

1 Input common (In-COM) 24 [V] (Note 1)

2 Command position 1 (PC1) Move to rear end (ST0) Command position 1 (PC1)

3 Command position 2 (PC2) Move to front end (ST1) Command position 2 (PC2)

4 Command position 4 (PC4)

5 Home return (HOME) Command position 8 (PC8)

6 Start (CSTR) Start (CSTR)

7 *Pause (*STP) *Pause (*STP) *Pause (*STP)

8 Position complete (PEND) Rear end (PE0) Position complete (PEND)

Home-return completion

(HEND)

10 Zone output (ZONE) Intermediate point (PE2) Zone output (ZONE)

11 *Alarm (*ALM) *Alarm (*ALM) *Alarm (*ALM)

12 Output common (Out-COM) 0 [V] (Note 1)

Move to intermediate point (ST2)

Front end (PE1)

PIO pattern

Command position 4 (PC4)

Home-return completion (HEND)

LED 11 illuminates when 24 V is supplied. LED1 illuminates when this signal turns ON. LED2 illuminates when this signal turns ON. LED3 illuminates when this signal turns ON. LED4 illuminates when this signal turns ON. LED5 illuminates when this signal turns ON. LED6 illuminates when this signal turns ON. LED7 illuminates when this signal turns ON. LED8 illuminates when this signal turns ON. LED9 illuminates when this signal turns ON. LED10 illuminates when this signal turns ON.

(Note 1) The input common and output common become 0 [V] and 24 [V], respectively, in the PNP specification.

[2] RCB-TU-PIO-AP/BP (When the control board is of the PNP specification)

TB3

0 (8-point type) 1 (3-point type) 2 (16-point type)

1 Input common (In-COM) 0 [V] (Note 2)

2 Command position 1 (PC1) Move to rear end (ST0) Command position 1 (PC1)

3 Command position 2 (PC2) Move to front end (ST1) Command position 2 (PC2)

4 Command position 4 (PC4)

5 Home return (HOME) Command position 8 (PC8)

6 Start (CSTR) Start (CSTR)

7 *Pause (*STP) *Pause (*STP) *Pause (*STP)

8 Position complete (PEND) Rear end (PE0) Position complete (PEND)

Home-return completion

(HEND)

10 Zone output (ZONE) Intermediate point (PE2) Zone output (ZONE)

11 *Alarm (*ALM) *Alarm (*ALM) *Alarm (*ALM)

12 Output common (Out-COM) 24 [V] (Note 2)

Move to intermediate point (ST2)

Front end (PE1)

PIO pattern

Command position 4 (PC4)

Home-return completion (HEND)

(Note 1) The input common and output common become 24 [V] and 0 [V], respectively, in the NPN specification.

Remarks

 Internal connection diagram [1] RCB-TU-PIO-A/B

Actuator end

Connector

6 circuits

4 circuits

Nonpolar input

photocoupler

Host system end

Input common

6 circuits

Fusing chip resistor

4 circuits

Output common

[2] PCB-TU-PIO-AP/BP

Actuator end

Connector

6 circuits

4 circuits

Nonpolar input

photocoupler

Host system end

Input common

6 circuits

Fusing chip resistor

4 circuits

Output common

 I/O interface specifications

Input Specifications

Specification item Description

Number of input points 6 points

Input voltage

 24VDC  10%

Input current 7 mA/point (bipolar)

Allowable leak current 1 mA/point (approx. 2 mA at normal temperature)

Operating voltage

ON voltage: 16 V min. (4.5 mA) OFF voltage: 5 V max. (1.3 mA)

Output Specifications

Specification item Description

Number of output points 4 points

Rated load voltage 24VDC

Maximum current 60 mA/point

Residual voltage 2 V or less/60 mA

Shorting/overcurrent protection

Fusing resistor (27 , 0.1 W)

5. Data Entry <Basics>

This actuator doesn’t use command words, so there is no need to create a program. All you need is to enter the target position in the position-data table, and the actuator will move to the specified position. Position data consists of number (No.), target position (Position), speed (Speed), acceleration/deceleration (ACC), push (Push), positioning band (Pos. band), and acceleration only MAX (ACC MAX). The description in parentheses is as displayed on the teaching pendant. The target position can be specified in two different modes: by absolute coordinate specification (absolute mode) in which the distance from the home is entered, or by relative coordinate specification (incremental mode) in which the incremental movement from the current position is entered.

Position-data table

No.

Position Note

Speed

Acceleration/

deceleration

Push

0 0 100 0.3 0 0.1 0 1 30 100 0.3 0 0.1 0

2 10 100 0.3 0 0.1 0

      

~ ~

 

100

 

100

 

0.3

 

When data is entered in the position column of the position-data table, the default values will be automatically entered in the remaining columns. Change the default values as necessary. To change a default value, change the corresponding parameters starting with “Default.” The default values vary depending on the actuator type.

This indicates that the incremental mode is active. (This symbol is displayed only on the teaching pendant. Separate columns for incremental specification are provided in the PC software.)

Positioning

band

 

0.1

Acceleration

only MAX

 

~ ~

Note: Enter position data first. Any attempt to enter other data before position data will be rejected. You can enter position data containing two decimal places. However, the controller only recognizes position data as a multiple of its minimum resolution. The minimum resolution of the controller varies depending on the actuator lead. For the above reason, the second decimal place in the entered position data may be rewritten

in accordance with the actuator lead.

Example: Entered value Stored value

50.01 50.03



5.1 Description of Position-Data Table

(1) No.

(2) Target position (Position)

(3) Speed (Speed)

(4) Acceleration/deceleration

(ACC)

Note: Enter appropriate values for speed and acceleration/deceleration by referring to 1.3, “Specifications”

and considering the installation conditions and shape of the load, to make sure the actuator will not receive excessive impact or vibration. Whether or not the values of speed and acceleration/deceleration should be raised has a lot to do with the transferring mass and how the actuator characteristics will change also varies depending on the model. Consult IAI’s Sales Engineering Section for the maximum values of speed and acceleration/deceleration you can enter.

 Indicate the position data number.

To enter an incremental movement, press the minus key in this column. On the teaching pendant, a “=” will be displayed between the number and position columns. The minus key need not be pressed in the absolute mode.

 Enter the target position to move the actuator to, in [mm].

Absolute mode: Enter the distance to the target actuator position from the

home.

Incremental mode: Enter the distance to the target actuator position from the

current position. A negative value can also be entered (for movement in the negative direction along the displayed coordinate axis).

No. Position

0 30 Absolute mode 30 mm from the home

2 3 100 Absolute mode 100 mm from the home

10 Incremental mode +10 mm from the current position

-10 Incremental mode -10 mm from the current position

 Enter the speed at which the actuator will be moved, in [mm/sec].

The default value varies depending on the actuator type.

 Enter the acceleration/deceleration at which the actuator will be moved, in [G].

Use the rated acceleration specified in the catalog, as a rule. This product can be used at higher accelerations to shorten the takt time, but only if the actual use conditions are such that the “load is significantly more than the rating.” To support the above function, the acceleration field in the position table accepts values greater than the rated acceleration.

Speed

Acceleration/deceleration (ACC)

Start Completion Time

Acceleration/deceleration G --- MIN 0.01 G (Slow rise) MAX 1.00 G (Quick rise)

(5) Push (Push)

 Select the positioning mode or push & hold mode.

The default value is “0.” 0: Positioning mode (= Normal operation) Other than 0: Push & hold mode [%]

 To select the push & hold mode, enter the current-limiting value for the servo

motor during push & hold operation. Enter an appropriate value up to 70% in accordance with the actuator type.

Be sure to refer to 5.1.1, “Relationship of Push Force at Standstill and Current-Limiting Value” that specifies the relationship of the push force to be applied to the load at standstill [kgf] on one hand, and the currentlimiting value on the other, for each actuator type.

Note: If the push force is too small, a false detection of push & hold condition may occur due to slide

resistance, etc., so exercise caution.

(6) Positioning band

(Pos. band)

 The function of the positioning band varies depending on whether the push &

hold setting in (5) is “0” or “other than 0.”

(A) Push = 0 (Positioning mode)

 In the positioning mode, enter the position-complete detection width

(distance to the target position), in [mm].

 The distance to the target position indicates the range prior to the target

position, upon entry of the actuator in which range a position complete signal will be output.

The default value is “0.1 [mm]” (Fig. A).

(B) Push = Other than 0 (Push & hold mode)

 Enter the maximum push amount (distance from the target) in the push &

hold mode, in [mm] (Fig. B).

 If the push direction corresponds to the negative direction along the

displayed coordinate axis, add a – (minus) sign to the entered value.

(5) Push = 0

Distance to the position set in (2)

Speed

Moving distance

(6) Positioning band (6) Positioning band

Fig. A Fig. B

(5) Push = Other than 0

Distance to the position set in (2)

Speed

Moving distance

(7) Acceleration only MAX

(ACC MAX)

 Select the specified acceleration or maximum acceleration by entering

“0” or “1.”

The default value is “0.”

0: Specified acceleration --- The value entered in (4) becomes the

actual acceleration/deceleration.

1: Maximum acceleration --- The maximum acceleration is applied only

during acceleration.

During deceleration, the value input in (4)

is used.

(7) Acceleration only MAX = 0 (7) Acceleration only MAX = 1

Speed

Acceleration/deceleration

set in (4)

Maximum acceleration

Speed

Acceleration/deceleration set in (4)

Moving distance

Note: A rough guide for enabling the acceleration only MAX function is when the actual payload capacity

is one-third the load rating or less. Check the payload rating by referring to 1.3, “Specifications.”

5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value

When performing operation in the push & hold mode, enter the current-limiting value (%) in the push column of the position-data table. Determine the current-limiting value (%) from the push force to be applied to the load at standstill. The graphs below illustrate the relationship of push force at standstill and current-limiting value for each actuator type:

● Slider type (1) SA6 type (2) SA7 type

Low-speed type Low-speed type

350

300

250

200

150

100

Push force (N)

20 30 40 50 60 70

Current-limiting value (%) Current-limiting value (%)

(Lead: 3 mm) (Lead: 4 mm)

160 140 120 100

80 60

40 20

Push force (N)

Medium-speed type

(Lead: 6 mm)

20 30 40 50 60 70

Current-limiting value (%) Current-limiting value (%)

80 70 60 50 40 30

Push force (N)

20 30 40 50 60 70

High-speed type

(Lead: 12 mm)

Current-limiting value (%) Current-limiting value (%)

900 800 700 600 500 400 300 200

Push force (N)

100

20 30 40 50 60 70

Medium-speed type

450 400 350 300 250 200 150 100

Push force (N)

20 30 40 50 60 70

(Lead: 8 mm)

High-speed type

250

200

150

100

Push force (N)

20 30 40 50 60 70

(Lead: 16 mm)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

● Rod type (1) RA54 type (2) RA64 type

Low-speed type Low-speed type

(Lead: 3 mm) (Lead: 4 mm)

350

300

250

200

150

100

Push force (N)

20 30 40 50 60 70

900 800 700 600 500 400 300 200

Push force (N)

100

20 30 40 50 60 70

Current-limiting value (%) Current-limiting value (%)

160 140 120 100

80 60

Push force (N)

20 30 40 50 60 70

80 70 60 50

ce (N)

40 30

Push fo

20 30 40 50 60 70

Medium-speed type

(Lead: 6 mm)

450 400 350 300 250 200 150

Push force (N)

100

20 30 40 50 60 70

Current-limiting value (%) Current-limiting value (%)

High-speed type

(Lead: 12 mm)

250

200

150

100

Push force (N)

20 30 40 50 60 70

Current-limiting value (%) Current-limiting value (%)

Medium-speed type

(Lead: 8 mm)

High-speed type

(Lead: 16 mm)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

5.2 Explanation of Modes

5.2.1 Positioning Mode Push = 0

Speed

Moving distance

5.2.2 Push & Hold Mode Push = Other than 0

(1) Load was contacted successfully

Speed

Moving distance

The actuator continues to push the load at the push force at standstill determined by the

Warning

The push speed is set as follows in accordance with the speed set in the position-data table:

Push speed 20 mm/sec Set speed

current-limiting value. Since the actuator is not inactive, exercise due caution when handling the machine in this condition.

Position complete signal

Output

Positioning band

Position complete signal

Output

Positioning band

20 mm/sec or more Less than 20 mm/sec

(1) The position complete output will turn

ON at a position preceding the target position by the positioning band.

(1) After reaching the target position, the actuator

will move at low speed (75 rpms). When the Pos. band set in the data table (see Note) is reached after the actuator contacts the load and the stepper motor current has reached the current-limiting value, the position complete output will turn ON.

Note: Set the parameter “Push & hold stop

judgment period.” The default value of “255 [msec]” is already entered.

The actuator is holding the load in position while pushing it.

Set speed

(2) Load was not contacted (missed)

Position complete signal is not output

Speed

Moving distance

Positioning band

(3) Load moves during push & hold operation

(a) Load moves in the pushed direction

Position complete signal

Output

Speed

Moving distance

(b) Load moves in the opposite direction (Actuator is pushed back by the reactive force of the load)

Speed

Moving distance

Positioning band

Position complete signal

Output

(1) After reaching the target position, the actuator

will move at low speed.

Even after contacting the load, the actuator will

move to the end of the positioning band if the stepper motor current is yet to reach the currentlimiting value.

The position complete output will not turn ON

even when the end of the positioning band is reached. (Provide a timeout check process after a sufficient period with a PLC.)

If the load moves in the pushed direction after the position complete output has turned ON, the actuator will push the load within the positioning band. If the current drops below the limiting value, the position complete signal will turn OFF. The signal will turn ON when the current rises to or above the limiting value.

If the actuator is pushed back after the position complete output has turned ON because the actuator thrust is smaller than the reactive force of the load, the actuator will be pushed back all the way until its thrust balances out with the reactive force of the load. The position complete output will remain ON.

(4) Positioning band was entered with a wrong sign

If the positioning band is entered with a wrong sign,

Speed

the position will deviate by twice the positioning band, as shown to the left, so exercise due caution.

Moving distance

Positioning

band

Positioning

band

5.2.3 Speed Change during Movement

Speed control involving multiple speed levels is possible in a single operation. The actuator speed can be decreased or increased at a certain point during movement. However, the position at which to implement each speed change must be set.

Position 1 Position 2 Position 1 Position 2 Position 1 Position 2 Position 3

5.2.4 Operation at Different Acceleration and Deceleration Settings

The actuator will accelerate and decelerate at different speeds if “1” is entered under “Acceleration only MAX” in the position data. The acceleration will conform to the maximum acceleration set according to the load, while the deceleration will conform to the value entered in “Acceleration/deceleration” of the position data.

Note: The maximum acceleration varies from actuator to actuator, but the limit is generally three times the

rated acceleration. Accordingly, enable this function only when the transferring mass is one-third the rating or less and you want to decelerate the actuator over a gradual acceleration curve when stopping. If this function is enabled when the transferring mass is equal to the rating, an overload error may occur. Exercise due caution because even if an overload error does not occur, the actuator will receive an excessive impact load and its life will be negatively affected. Check the payload rating by referring to 1.3, “Specifications.”

Speed

Maximum acceleration accordin

to the load

Time

Deceleration can be set freely

5.2.5 Pause

The actuator can be paused during movement using an external input signal (*pause). The pause signal uses the contact B logic (always ON) to ensure safety. Turning OFF the *pause input will cause the actuator to decelerate to a stop, while turning it ON will allow the actuator to complete the remaining operation.

*Pause signal

ON ON

OFF

Actuator operation

Target position

(Note) During deceleration, the acceleration/deceleration set in the position table under the currently executed

position number is used.

5.2.6 Zone Signal Output

A signal will be output when the actuator enters the specified zone. The zone signal will turn ON when the actuator enters the zone predefined by the applicable parameters. (The zone can be set arbitrarily.)

Zone signal

Actuator operation

Zone signal setting range

5.2.7 Home Return

After the power is turned on, home return must be executed to establish the home. Upon occurrence of a cold-start level error, the power must be reconnected to restore the system. In this case, home return is also required after the reconnection of power.

Which home return method is used will vary depending on the PIO pattern selected.  Home return using a dedicated input [PIO pattern = 0 (8 points)]

Home return can be executed using the home return (HOME) input. Turning ON this input will execute home return regardless of whether or not it has already been executed once. When the home return is complete, the home return completion (HEND) output will turn ON.

 Home return not using a dedicated input [PIO pattern = 2 (16 points)]

Even if home return has not been executed yet, issuing a start command by specifying a position will cause the actuator to return to the home before moving to the specified position.

 For details, refer to 7.2, “How to Execute Home Return.”

6. Operation in the “3 Points (Air Cylinder)” Mode <Practical Operation>

6.1 Overview of the “3 Points” Mode

This mode provides a control method adjusted to that of an air cylinder by assuming that the ERC is used as an air cylinder. The key differences between the ERC and an air cylinder are summarized below. Perform proper control by referring to this table.

Item Air cylinder ERC

Drive method Air pressure supplied

via electromagnetic

valve control Target position setting

Target position detection Speed setting

Acceleration/ deceleration setting

Mechanical stopper

(including shock

absorber)

An external detection

sensor, such as a reed

switch, is installed.

Adjusted by a speed

controller.

Determined in

accordance with the

load, supplied air

volume, as well as the

performance of the

speed controller and

electromagnetic valve. Position check upon power ON

Determined by an

external detection

sensor, such as a reed

switch.

Ball screw/timing belt driven by a motor

Desired coordinates are entered in the [Target position] field of the position table. The coordinates can be typed in from the number keys on the PC keyboard or on the teaching pendant, or set directly by moving the actuator to the target position. Determined based on the internal coordinates provided by the position information from the position detector (encoder). Accordingly, external detection sensor is not required. A desired feed speed is entered in the [Speed] field of the position table (unit: mm/sec). Note that the rated speed is automatically set as the initial value. A desired acceleration/deceleration is entered in the [Acceleration/deceleration] field of the position table (unit: 0.01 G). (Reference) 1 G = Gravitational acceleration Note that the rated acceleration/deceleration is automatically set as the initial value. Since the acceleration/deceleration can be set in fine steps, a gradual acceleration/deceleration curve can be programmed. Immediately after the power is turned on, the controller cannot identify the current position because the mechanical coordinates have been lost. Therefore, when the first movement command is issued after the power has been input, the controller will automatically perform home return before moving the actuator to the target position.

[1]

[2]

[3]

Home

osition

Power is turned on here.

Target position

[1] The actuator moves at the home return speed toward the

mechanical end on the motor side.

[2] The actuator hits the mechanical end and turns back, and then

stops temporarily at the home position.

[3] The actuator moves to the target position at the speed

specified in the [Speed] field of the position table.

(Note) Pay attention not to allow any obstacle in the travel

path of the actuator during home return.

The relationships of movement command inputs/position complete outputs and corresponding position numbers are shown below. For easier identification, each input/output signal has a name similar to the naming convention used with air cylinders. However, note that the target position is determined by the value set in the [Target position] field under each position number. Therefore, changing the magnitude correlation of the settings in Nos. 0 to 2 will change the meanings of the corresponding input/output signals. Accordingly, the settings in the respective position numbers should match the semantic meanings of the corresponding signal names used in this operation manual, unless doing so will pose a problem.

Input signal Output signal Target position

Rear end move (ST0) Rear end complete (PE0)

Front end move (ST1) Front end complete (PE1)

Intermediate point move (ST2) Intermediate point complete (PE2)

Setting in the [Target position] field under position No. 0 Example: 5 mm

Setting in the [Target position] field under position No. 1 Example: 390 mm

Setting in the [Target position] field under position No. 2 Example: 200 mm

 Positioning relationships on the Robo Cylinder This example assumes the use of a slider type actuator with a 400 mm stroke.

[Motor side] [Counter-motor side]

Home (0 mm)

Rear end complete (5 mm)

Intermediate point complete (200 mm)

 Position table (Field(s) within thick line must be entered.)

No. Position Speed Acceleration/deceleration Push Positioning band Acceleration only MAX

Front end complete (390 mm)

0 5 500 0.3 0 0.1 0

1 390 500 0.3 0 0.1 0

2 200 500 0.3 0 0.1 0

6.2 How to Start

(1) Confirm that the connector end (CN1) of the relay cable is firmly plugged into the connector on the actuator

cable. (2) Connect the PLC and the parallel I/O. (3) If the actuator has brake, set the brake release switch to OFF. (4) Supply 24 VDC to the control power supply. Cut off the motor-drive power supply (actuate an emergency stop) beforehand. (5) Confirm that the slider or rod is not contacting the mechanical end. If the slider or rod is contacting the

mechanical end, or when the slider or rod is positioned between the mechanical end and home, move the

slider/rod away from the home position toward the direction opposite to the mechanical end. If the actuator is equipped with a brake, move the slider/rod after releasing the brake by turning on the

brake release switch. At this time, pay attention to prevent the work from falling by its dead weight and

protect your hand, robot, and the work from injuries/damages.

If the screw lead is short and you cannot adjust it manually, set the excited-phase signal detection direction

in parameter No. 28 to opposite the mechanical end.

Warning: Turning on the servo while the slider or rod is still contacting the mechanical end may

disable accurate detection of the excited phase, resulting in malfunction or excitation detection error.

(6) Connect a PC or teaching pendant and set the minimum parameters required.

 If the pause input is not used, set parameter No. 15 “Pause input disable selection” to “1.”  Set parameter No. 25 “PIO pattern selection” to “1” (this setting is required).  If you want to use the movement command input based on the “edge mode,” set parameter No. 27 to “1.”

Refer to 8, “Parameters” for details.

(7) Cancel the emergency stop so that the motor drive power will be supplied.

 The controller servo will be turned on and a green LED lamp will illuminate on the motor cover. (8) If the pause signal (*STP) is enabled, turn the signal ON from the PLC.

 A red LED lamp indicates an alarm. Remove the cause of the alarm.

For details, refer to 9, “Troubleshooting.” (9) Perform home return.

 Overview of operation on the teaching pendant

 On the RCA-T, select the Edit/Teach screen, bring the cursor to *Home in the sub-display area, and then

press the ENTER key.

 On the RCA-E, select the Teach/Play screen, scroll the pages until *Home Return is shown, and then

press the ENTER key.

 On the RCB-J, the screen showing RUN Key  Home Return is displayed automatically. Press the

RUN key.

 Overview of operation in the PC software

In the main window, select the applicable position data, and then click Home.

For details of each operation, refer to the operation manual for the applicable teaching pendant

or PC software.

If the actuator does not perform home return, confirm that the *pause signal is ON, the motor-drive power supply is receiving power, and no error messages are displayed, among others.

(10) Set the target position, speed, acceleration/deceleration, positioning band and other data in the position

table. For details on how to set data in the position table, refer to the operation manual for the teaching

pendant or PC software, whichever is applicable. Now, you can operate the actuator automatically via control from the PLC.

Note: Move the actuator to the target position after confirming that the *ALM output is ON and the

motor drive power is supplied.

Timing chart at start

Motor-drive power supply

Input of 24-VDC power supply

LED lamp

Alarm output (*ALM)

Pause input (*STP)

Home return

Cut off

Initial parameter setting

Red

Supplied

Green

Pause is released.

Movement starts

Mechanical end

Home position

Create a position table via teaching pendant or PC operation.

6.3 Moving Operation

First, make the controller ready to accept movement commands by referring to 6.2, “How to Start.” Example of use in operation) Turn on the power, and then cause the actuator to move back and forth between

the rear end (5 mm) and front end (390 mm) via an intermediate point (200 mm).

ERC controller

[1] [3] [12]

[8] [11]

[4] [7]

[2] [5]

[10] [13]

[6] [9]

Signal name

Rear end move

Front end move

Intermediate point move

*Pause

Rear end complete

Front end complete

Intermediate point complete

*Alarm

PIO

7. Operation in the “8 Points” and “16 Points” Modes <Practical Operation>

7.1 How to Start

(1) Confirm that the connector end (CN1) of the relay cable is firmly plugged into the connector on the actuator

cable. (2) Connect the PLC and the parallel I/O. (3) If the actuator has a brake, set the brake release switch to OFF. (4) Supply 24 VDC to the control power supply.

Cut off the motor-drive power supply (actuate an emergency stop) beforehand. (5) Confirm that the slider or rod is not contacting the mechanical end. If the slider or rod is contacting the

mechanical end, or when the slider or rod is positioned between the mechanical end and home, move the

slider/rod away from the home position toward the direction opposite to the mechanical end. If the actuator is equipped with a brake, move the slider/rod after releasing the brake by turning on the

brake release switch. At this time, pay attention to prevent the work from falling by its dead weight and

protect your hand, robot, and the work from injuries/damages.

If the screw lead is short and you cannot adjust it manually, set the excited-phase signal detection direction

in parameter No. 28 to opposite the mechanical end.

Warning: Turning on the servo while the slider or rod is still contacting the mechanical end

may disable accurate detection of the excited phase, resulting in malfunction or excitation detection error.

(6) Connect a PC or teaching pendant and set the minimum parameters required.

 If the pause input is not used, set parameter No. 15 “Pause input disable selection” to “1.”  To select “16 points,” set parameter No. 25 “PIO pattern selection” to “2” (this setting is required).

For details, refer to 8, “Parameters.”

(7) Cancel the emergency stop so that the motor drive power will be supplied.

 The controller servo will be turned on and a green LED lamp will illuminate on the motor cover. (8) If the pause signal (*STP) is enabled, turn the signal ON from the PLC.

 The position complete output (PEND) will turn ON.

 A red LED lamp indicates an alarm. Remove the cause of the alarm.

For details, refer to 9, “Troubleshooting.” (9) Perform home return.

 Overview of operation on the teaching pendant

 On the RCA-T, select the Edit/Teach screen, bring the cursor to *Home in the sub-display area, and then

press the ENTER key.

 On the RCA-E, select the Teach/Play screen, scroll the pages until *Home Return is shown, and then

press the ENTER key.

 On the RCB-J, the screen showing RUN Key  Home Return is displayed automatically. Press the

RUN key.

 Overview of operation in the PC software

In the main window, select the applicable position data, and then click Home.

For details of each operation, refer to the operation manual for the applicable teaching pendant

or PC software.

IAI America ERC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

CAUTION

Table of Contents

Safety Guide

1. Overview

1.1 Introduction

1.2 Meaning of the Model Name

1.3 Specifications

1.4 Safety Precautions

1.5 Warranty Period and Scope of Warranty

1.6 Transportation and Handling

1.7 Installation Environment and Noise Elimination

1.8 Cabling

2. Installation

2.1 Name of Each Part

2.2 Installation

3. Wiring

3.1 Basic Structure

3.2 I/O Connections for PIO Pattern 1 [3 Points] (Air Cylinder)

3.3 I/O Connections for PIO Pattern 0 [8 Points]

3.4 I/O Connections for PIO Pattern 2 [16 Points]

3.5 Configuration Using a SIO Converter

3.6 Configuration Using an Insulated PIO Terminal Block

3.7 Configuration Using Both SIO Converter and Insulated PIO Terminal Block

3.8 Controlling Multiple Axes via Serial Communication

3.9 Emergency-Stop Circuit

3.10 Relay Cable

4. Electrical Specifications

4.1 Controller

4.2 I/O Signal Interface Circuit

4.3 SIO Converter (Optional)

4.4 Insulated PIO Terminal Block (Optional)

5. Data Entry <Basics>

5.1 Description of Position-Data Table

5.2 Explanation of Modes

6. Operation in the “3 Points (Air Cylinder)” Mode <Practical Operation>

6.1 Overview of the “3 Points” Mode

6.2 How to Start

6.3 Moving Operation

7. Operation in the “8 Points” and “16 Points” Modes <Practical Operation>

7.1 How to Start