IAI America ERC2 User Manual

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Operation Manual Seventh Edition

ERC2

Actuator with Integrated Controller (SIO Type)

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 or DVD 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. Using Multiple 24-V Power Supplies

If multiple 24-V power supplies are used, always connect the 0-V lines of all power supplies. If not, damage to the controller board, SIO converter or other components may occur.

[Connection Example]

24V

24-V power supply

[1]

24-V power supply

[2]

24-V power supply

[3]

24-V power supply

[4]

24-V power supply

[5]

SIO

converter

PLC PIO unit

Actuator 1

Actuator 2

Actuator 3

Actuator 4

CAUTION

2. PC Software and Teaching Pendant Models

This product offers new functions not available in the conventional ERC series. To support these new functions, the communication protocol has been changed to a general Modbuscompliant protocol. Accordingly, the PC software programs and teaching pendants that have been used with the ERC series are no longer compatible with the ERC2 series. Select a compatible program or teaching pendant from among the models listed below.

Model nu

mber Remarks

PC software (with RS232C communication cable)

RCM-101-MW

PC software (with USB communication cable)

RCM-101-USB

Teaching pendant RCM-T, RCM-TD

Simple teaching pendant RCM-E

Data setting unit RCM-P

These software programs/teaching pedants can be used with the ERC series.

3. Backup of Latest Data

The built-in controller of this actuator uses a nonvolatile memory to store position table data and parameters. Normally data is retained after the power has been cut off, but stored data will be lost if the nonvolatile memory is damaged. Regular backup of latest position table data and parameters not only ensures that your important data is safeguarded, but it also saves the data recovery time when a need arises to replace the controller board for some reason. To back up your data, do one of the following: [1] Save the data to a hard disk or other storage media from the PC software. [2] Create a position table sheet or parameter sheet and write down the settings.

4. Pamphlet on Modbus Protocols

You can download a pamphlet compiling Modbus protocols from the operation manual download page on IAI’s website:

website:www.intelligentactuator.com

If you wish to obtain this pamphlet, please contact your IAI sales representative.

CE Marking

If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.

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

1. Overview ................................................................................................................................................ 9

1.1 Introduction .................................................................................................................................. 9

1.2 Key Features and Functions...................................................................................................... 10

1.3 Differences from Air Cylinder Control ........................................................................................11

1.4 Meaning of the Model Number ..................................................................................................13

1.5 Specifications............................................................................................................................. 14

1.5.1 Correlation Diagrams of Speed and Payload Capacity – Slider Type .......................... 15

1.5.2 Correlation Diagrams of Speed and Payload Capacity – Rod Type............................. 16

1.5.3 The sound pressure level of this product does not exceed 70 dB................................ 17

1.6 Warranty ................................................................................................................................... 20

1.7 Transportation and Handling ..................................................................................................... 20

1.7.1 Handling before Unpacking .......................................................................................... 20

1.7.2 Handling after Unpacking.............................................................................................. 20

1.8 Installation Environment and Noise Elimination ........................................................................ 21

1.8.1 Installation Environment................................................................................................ 21

1.8.2 Storage Environment .................................................................................................... 21

1.8.3 Power Supply................................................................................................................ 22

1.8.4 Noise Elimination .......................................................................................................... 22

1.9 Cabling....................................................................................................................................... 24

2. Installation............................................................................................................................................ 27

2.1 Name of Each Part .................................................................................................................... 27

2.1.1 Slider Type (SA6C/SA7C)............................................................................................. 27

2.1.2 Rod Type (RA6C/RA7C)............................................................................................... 28

2.1.3 (1) Rod Type with a Single Guide (RGS6C/RGS7C).................................................... 28

(2) Rod Type with Double Guides (RGD6C/RGD7C)................................................... 28

2.2 Installation.................................................................................................................................. 29

2.2.1 Slider Type.................................................................................................................... 29

2.2.2 Rod Type.......................................................................................................................30

2.2.3 Installing the Load......................................................................................................... 32

3. Electrical Specifications ....................................................................................................................... 34

3.1 Controller ................................................................................................................................... 34

3.2 Input/Output Interfaces .............................................................................................................. 35

3.2.1 Extension Cable............................................................................................................ 36

3.3 SIO Converter (Optional)........................................................................................................... 37

4. Wiring ................................................................................................................................................... 39

4.1 Basic Configuration with SIO Converter.................................................................................... 39

4.1.1 SIO Communication Connection Using a Relay Terminal Block ..................................41

4.1.2 SIO Communication Connection Using a 4-Way Junction ........................................... 42

4.1.3 Address Assignment..................................................................................................... 43

4.2 Configuration Using a Gateway Unit ......................................................................................... 44

4.2.1 SIO Communication Connection Using a Relay Terminal Block ..................................44

4.2.2 SIO Communication Connection Using a 4-Way Junction ........................................... 45

4.2.3 Connecting an Emergency Stop Circuit, Etc.................................................................46

5. Explanation of Operating Functions..................................................................................................... 47

5.1 Description of Position Table ..................................................................................................... 48

5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value ........................... 52

5.2 Data Set in the Numerical Specification Mode .......................................................................... 54

5.3 Explanation of Functions ........................................................................................................... 54

5.3.1 Control Signals and Control Data ................................................................................. 56

5.3.2 Timings after Power On ................................................................................................62

5.3.3 Home Return Operation................................................................................................ 64

5.3.4 Positioning Operation.................................................................................................... 66

5.3.5 Push & Hold Operation ................................................................................................. 70

5.3.6 Pause............................................................................................................................ 74

5.3.7 Speed Change during Movement................................................................................. 75

5.3.8 Operation at Different Acceleration and Deceleration .................................................. 77

5.3.9 Zone Signal................................................................................................................... 78

5.3.10 Pitch Feed by Incremental Specification.......................................................................79

5.3.11 Power-Saving Mode at Standby Positions....................................................................83

6. Parameter Settings .............................................................................................................................. 84

6.1 Parameter Table ........................................................................................................................ 84

6.2 Detailed Explanation of Parameters.......................................................................................... 85

6.2.1 Parameters Relating to the Actuator Stroke Range......................................................85

6.2.2 Parameters Relating to the Actuator Operating Characteristics................................... 87

6.2.3 Parameters Relating to the External Interface.............................................................. 91

6.2.4 Servo Gain Adjustment................................................................................................. 93

7. Troubleshooting ................................................................................................................................... 95

7.1 Action to Be Taken upon Occurrence of Problem...................................................................... 95

7.2 Alarm Level Classification..........................................................................................................96

7.2.1 How to Reset Alarms ....................................................................................................96

7.3 Alarm Description and Cause/Action......................................................................................... 97

7.4 Messages Displayed during Operation Using the Teaching Pendant or PC Software............ 102

7.5 Specific Problems.................................................................................................................... 104

8. Maintenance and Inspection.............................................................................................................. 106

8.1 Inspection Items and Schedule ...............................................................................................106

8.2 Visual Inspection of Appearance ............................................................................................. 106

8.3 Cleaning................................................................................................................................... 106

8.4 Internal Check (Slider Type) .................................................................................................... 107

8.5 Internal Cleaning (Slider Type) ................................................................................................ 108

8.6 Greasing the Guide (Slider Type) ............................................................................................ 108

8.7 Greasing the Ball Screw (Slider Type).....................................................................................110

8.8 Greasing the Rod Slide Surface.............................................................................................. 111

8.9 Motor Replacement Procedure................................................................................................112

9. Operation Examples .......................................................................................................................... 114

10. Appendix ........................................................................................................................................... 115

.......................................................................................................................... 115

..........................................................................................................................115

..........................................................................................................................116

10.1 External Dimensions

10.1.1 ERC2-SA6C

10.1.2 ERC2-SA7C

10.1.3 ERC2-RA6C

10.1.4 ERC2-RA7C

10.1.5 ERC2-RGS6C

10.1.6 ERC2-RGS7C

10.1.7 ERC2-RGD6C

10.1.8 ERC2-RGD7C

10.2

Recording of Position Table Parameter Records

10.3

................................................................................... ....................................... 117

................................................................................... ................................ ....... 118

................................................................................... .................................... 119

................................................................................... .................................... 120

................................................................................... ................................ .... 120

................................................................................... ............................. 121

................................................................................... ........................................... 124

Change History......................... ....................................................................................................... 125

Safety Guide

“Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product.

Safety Precautions for Our Products

The common safety precautions for the use of any of our robots in each operation.

No.

1 Model

Operation

Description

Selection

Description

Ɣ This product has not been planned and designed for the application where

high level of safety is required, so the guarantee of the protection of human life is impossible. Accordingly, do not use it in any of the following applications.

1) Medical equipment used to maintain, control or otherwise affect human life or physical health.

2) Mechanisms and machinery designed for the purpose of moving or transporting people (For vehicle, railway facility or air navigation facility)

3) Important safety parts of machinery (Safety device, etc.)

Ɣ Do not use the product outside the specifications. Failure to do so may

considerably shorten the life of the product.

Ɣ Do not use it in any of the following environments.

1) Location where there is any inflammable gas, inflammable object or explosive

2) Place with potential exposure to radiation

3) Location with the ambient temperature or relative humidity exceeding the specification range

4) Location where radiant heat is added from direct sunlight or other large heat source

5) Location where condensation occurs due to abrupt temperature changes

6) Location where there is any corrosive gas (sulfuric acid or hydrochloric acid)

7) Location exposed to significant amount of dust, salt or iron powder

8) Location subject to direct vibration or impact

Ɣ For an actuator used in vertical orientation, select a model which is

equipped with a brake. If selecting a model with no brake, the moving part may drop when the power is turned OFF and may cause an accident such as an injury or damage on the work piece.

No.

Operation

Description

2 Transportation Ɣ When carrying a heavy object, do the work with two or more persons or

utilize equipment such as crane.

Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ When in transportation, consider well about the positions to hold, weight

and weight balance and pay special attention to the carried object so it would not get hit or dropped.

Ɣ Transport it using an appropriate transportation measure.

The actuators available for transportation with a crane have eyebolts attached or there are tapped holes to attach bolts. Follow the instructions in the instruction manual for each model.

Ɣ Do not step or sit on the package. Ɣ Do not put any heavy thing that can deform the package, on it. Ɣ When using a crane capable of 1t or more of weight, have an operator

who has qualifications for crane operation and sling work.

Ɣ When using a crane or equivalent equipments, make sure not to hang a

load that weighs more than the equipment’s capability limit.

Ɣ Use a hook that is suitable for the load. Consider the safety factor of the

hook in such factors as shear strength.

Ɣ Do not get on the load that is hung on a crane. Ɣ Do not leave a load hung up with a crane. Ɣ Do not stand under the load that is hung up with a crane.

3 Storage and

Preservation

Ɣ The storage and preservation environment conforms to the installation

environment. However, especially give consideration to the prevention of condensation.

Ɣ Store the products with a consideration not to fall them over or drop due to

an act of God such as earthquake.

4 Installation

and Start

(1) Installation of Robot Main Body and Controller, etc. Ɣ Make sure to securely hold and fix the product (including the work part). A

fall, drop or abnormal motion of the product may cause a damage or injury. Also, be equipped for a fall-over or drop due to an act of God such as earthquake.

Ɣ Do not get on or put anything on the product. Failure to do so may cause

an accidental fall, injury or damage to the product due to a drop of anything, malfunction of the product, performance degradation, or shortening of its life.

Ɣ When using the product in any of the places specified below, provide a

sufficient shield.

1) Location where electric noise is generated

2) Location where high electrical or magnetic field is present

3) Location with the mains or power lines passing nearby

4) Location where the product may come in contact with water, oil or chemical droplets

No.

Operation

Description

4 Installation

and Start

Description

(2) Cable Wiring Ɣ Use our company’s genuine cables for connecting between the actuator

and controller, and for the teaching tool.

Ɣ Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not

coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.

Ɣ Perform the wiring for the product, after turning OFF the power to the unit,

so that there is no wiring error.

Ɣ When the direct current power (+24V) is connected, take the great care of

the directions of positive and negative poles. If the connection direction is not correct, it might cause a fire, product breakdown or malfunction.

Ɣ Connect the cable connector securely so that there is no disconnection or

looseness. Failure to do so may cause a fire, electric shock or malfunction of the product.

Ɣ Never cut and/or reconnect the cables supplied with the product for the

purpose of extending or shortening the cable length. Failure to do so may

cause the product to malfunction or cause fire. (3) Grounding Ɣ The grounding operation should be performed to prevent an electric shock

or electrostatic charge, enhance the noise-resistance ability and control

the unnecessary electromagnetic radiation. Ɣ For the ground terminal on the AC power cable of the controller and the

grounding plate in the control panel, make sure to use a twisted pair cable

with wire thickness 0.5mm

(AWG20 or equivalent) or more for grounding work. For security grounding, it is necessary to select an appropriate wire thickness suitable for the load. Perform wiring that satisfies the specifications (electrical equipment technical standards).

Ɣ Perform Class D Grounding (former Class 3 Grounding with ground

resistance 100Ω or below).

No.

4 Installation

Operation

Description

and Start

Description

(4) Safety Measures Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ When the product is under operation or in the ready mode, take the safety

measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range. When the robot under operation is touched, it may result in death or serious injury.

Ɣ Make sure to install the emergency stop circuit so that the unit can be

stopped immediately in an emergency during the unit operation.

Ɣ Take the safety measure not to start up the unit only with the power turning

ON. Failure to do so may start up the machine suddenly and cause an

injury or damage to the product.

Ɣ Take the safety measure not to start up the machine only with the

emergency stop cancellation or recovery after the power failure. Failure to

do so may result in an electric shock or injury due to unexpected power input.

Ɣ When the installation or adjustment operation is to be performed, give

clear warnings such as “Under Operation; Do not turn ON the power!” etc.

Sudden power input may cause an electric shock or injury.

Ɣ Take the measure so that the work part is not dropped in power failure or

emergency stop.

Ɣ Wear protection gloves, goggle or safety shoes, as necessary, to secure

safety.

Ɣ Do not insert a finger or object in the openings in the product. Failure to do

so may cause an injury, electric shock, damage to the product or fire.

Ɣ When releasing the brake on a vertically oriented actuator, exercise

precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

5 Teaching Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ Perform the teaching operation from outside the safety protection fence, if

possible. In the case that the operation is to be performed unavoidably inside the safety protection fence, prepare the “Stipulations for the

Operation” and make sure that all the workers acknowledge and

understand them well.

Ɣ When the operation is to be performed inside the safety protection fence,

the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency.

Ɣ When the operation is to be performed inside the safety protection fence,

in addition to the workers, arrange a watchman so that the machine can be stopped any time in an emergency. Also, keep watch on the operation

so that any third person can not operate the switches carelessly.

Ɣ Place a sign “Under Operation” at the position easy to see. Ɣ When releasing the brake on a vertically oriented actuator, exercise

precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

* Safety protection Fence : In the case that there is no safety protection

fence, the movable range should be indicated.

No.

Operation

Description

6 Trial Operation Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ After the teaching or programming operation, perform the check operation

one step by one step and then shift to the automatic operation.

Ɣ When the check operation is to be performed inside the safety protection

fence, perform the check operation using the previously specified work procedure like the teaching operation.

Ɣ Make sure to perform the programmed operation check at the safety

speed. Failure to do so may result in an accident due to unexpected motion caused by a program error, etc.

Ɣ Do not touch the terminal block or any of the various setting switches in

the power ON mode. Failure to do so may result in an electric shock or malfunction.

7 Automatic

Operation

Ɣ Check before starting the automatic operation or rebooting after operation

stop that there is nobody in the safety protection fence.

Ɣ Before starting automatic operation, make sure that all peripheral

equipment is in an automatic-operation-ready state and there is no alarm indication.

Ɣ Make sure to operate automatic operation start from outside of the safety

protection fence.

Ɣ In the case that there is any abnormal heating, smoke, offensive smell, or

abnormal noise in the product, immediately stop the machine and turn OFF the power switch. Failure to do so may result in a fire or damage to the product.

Ɣ When a power failure occurs, turn OFF the power switch. Failure to do so

may cause an injury or damage to the product, due to a sudden motion of the product in the recovery operation from the power failure.

No.

8 Maintenance

Operation

Description

and Inspection

Description

Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ Perform the work out of the safety protection fence, if possible. In the case

that the operation is to be performed unavoidably inside the safety

protection fence, prepare the “Stipulations for the Operation” and make

sure that all the workers acknowledge and understand them well.

Ɣ When the work is to be performed inside the safety protection fence,

basically turn OFF the power switch.

Ɣ When the operation is to be performed inside the safety protection fence,

the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency.

Ɣ When the operation is to be performed inside the safety protection fence,

in addition to the workers, arrange a watchman so that the machine can be stopped any time in an emergency. Also, keep watch on the operation so that any third person can not operate the switches carelessly.

Ɣ Place a sign “Under Operation” at the position easy to see. Ɣ For the grease for the guide or ball screw, use appropriate grease

according to the Instruction Manual for each model.

Ɣ Do not perform the dielectric strength test. Failure to do so may result in a

damage to the product.

Ɣ When releasing the brake on a vertically oriented actuator, exercise

precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

Ɣ The slider or rod may get misaligned OFF the stop position if the servo is

turned OFF. Be careful not to get injured or damaged due to an unnecessary operation.

Ɣ Pay attention not to lose the cover or untightened screws, and make sure

to put the product back to the original condition after maintenance and inspection works.

Use in incomplete condition may cause damage to the product or an injury.

* Safety protection Fence : In the case that there is no safety protection

fence, the movable range should be indicated.

9 Modification

and Dismantle

Ɣ Do not modify, disassemble, assemble or use of maintenance parts not

specified based at your own discretion.

10 Disposal Ɣ When the product becomes no longer usable or necessary, dispose of it

properly as an industrial waste.

Ɣ When removing the actuator for disposal, pay attention to drop of

components when detaching screws.

Ɣ Do not put the product in a fire when disposing of it.

The product may burst or generate toxic gases.

11 Other Ɣ Do not come close to the product or the harnesses if you are a person

who requires a support of medical devices such as a pacemaker. Doing so may affect the performance of your medical device.

Ɣ See Overseas Specifications Compliance Manual to check whether

complies if necessary.

Ɣ For the handling of actuators and controllers, follow the dedicated

instruction manual of each unit to ensure the safety.

Alert Indication

The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the Instruction Manual for each model.

Level Degr

Danger

Warning

Caution

Notice

This indicates an imminently hazardous situation which, if the product is not handled correctly, will result in death or serious injury.

This indicates a potentially hazardous situation which, if the product is not handled correctly, could result in death or serious injury.

This indicates a potentially hazardous situation which, if the product is not handled correctly, may result in minor injury or property damage.

This indicates lower possibility for the injury, but should be kept to use this product properly.

ee of Danger and Damage Symbol

Danger

Warning

Caution

Notice

Caution in Handling

1. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings.

If the actuator is operated at a speed or acceleration/deceleration exceeding the allowable value, abnormal noise or vibration, failure, or shorter life may result. In the case of interpolated operation of combined axes, the speed and acceleration/deceleration settings should correspond to the minimum values among all combined axes.

2. Keep the load moment within the allowable value.

If the actuator is operated under a load equal to or greater than the allowable load moment, abnormal noise or vibration, failure, or shorter life may result. In an extreme case, flaking may occur.

3. Make sure to attach the actuator properly by following this instruction manual.

Using the product with the actuator not being certainly retained or affixed may cause abnormal noise, vibration, malfunction or shorten the product life.

1. Overview

1.1 Introduction

Thank you for purchasing the Easy All-in-One ROBO Cylinder (hereinafter referred to as “ERC2-SE”).

This product retains all benefits of the conventional ERC series, while incorporating new features that provide greater convenience and enhanced safety to the users. Among the ERC2 Series actuators, this product can be operated via serial communication in the position number specification mode or the direct numerical specification mode. The following two communication patterns are supported by serial communication systems: [1] Communicate with a host PLC, etc., via a gateway unit in various field network environments (DeviceNet,

CC-Link and Profibus). [2] Communicate serially with a PC or PLC via a SIO converter based on the RS-232C protocol. Please read this manual carefully and handle the product with utmost care while ensuring its correct operation. It is advised that you also peruse the operation manual for your gateway unit as well as the Operation Manual for Serial Communication Protocol.

When starting your system or in the event of failure, also refer to the operation manuals for the teaching pendant, PC software and other components you are using with this product.

This manual does not cover all possible operations other than normal operations, or unexpected events such as complex signal changes resulting from operating the product at critical timings. Accordingly, think of any item not specifically mentioned in this manual as “prohibited.”

* 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. Overview

1.2 Key Features and Functions

(1) Input/output of control signals by means of RS485 serial communication (conforming to the Modbus

protocol)

(2) 64 positioning points

(3) Variable zone output boundaries

Before, zone output boundaries were set by parameters and therefore fixed. For greater convenience, this product permits setting of zone output boundaries in the position table. (Available in the position number specification mode only) Set desired boundaries to prevent contact with peripheral equipment, shorten the tact time, etc.

(4) Different acceleration and deceleration settings (Available in the position number specification mode only)

Acceleration and deceleration can be set differently in the position table. In situations where shock and vibration upon stopping must be minimized depending on the material or shape of the load, you can decrease only the deceleration to allow the actuator to stop along a gradual deceleration curve.

(5) Limitation of moving speed during adjustment by trial operation

During adjustment by trial operation, the moving speed of the actuator can be limited to ensure safety.

(6) Power-saving measure

In general, pulse motors generate greater holding current than AC servo motors in a standstill state. Accordingly, we provide a power-saving mode to conserve electricity in situations where the actuator stands by for a long period.

1. Overview

1.3 Differences from Air Cylinder Control

This section explains the key differences between an air cylinder and this controller for users who are familiar with air cylinders but have never used a motorized cylinder before. Refer to the table below to perform appropriate controls.

Item Air cylinder This controller

Drive method Driven by air pressure

based on electromagnetic valve control.

Driven by a ball screw or timing belt using a pulse motor.

Target position setting

Mechanical stopper (including a shock absorber)

[1] Position number specification mode Enter a coordinate in the [Position] field of the position table. You can key in a desired coordinate using the number keys on a PC (keyboard)/teaching pendant, or move the actuator to a desired position and then write the coordinate to the position table directly. Example) Entries on a 400-mm actuator

[2] Numerical specification mode: Specify a desired value

directly.

Target position detection

A reed switch or other external detection sensor is installed.

Whether or not the target position has been reached is determined based on the internal coordinate information received from the position detector (encoder). Accordingly, no external detection sensor is required.

Speed setting Adjusted using a speed

controller.

[1] Enter a feed speed in the [Speed] field of the position

table (in mm/sec). Initially, the default speed has been set automatically. [2] Specify a desired value directly.

Acceleration/ deceleration setting

In accordance with the load, air supply volume, and speed controller/electromagnetic valve performance.

[1] Enter an acceleration or deceleration in the [Acceleration]

or [Deceleration] field of the position table (in units of 0.01

G). Reference: 1 G = Gravitational acceleration that generates when the actuator drops freely. Initially, the default acceleration and deceleration have been set automatically. [2] Specify a desired value directly. Since acceleration and deceleration can be set finely, you can define a gradual deceleration/acceleration curves.

Larger acceleration/deceleration values set steeper curves, while smaller acceleration/deceleration values set more gradual curves.

Position No. Position

Acceleration

Deceleration

Movement start position

End position

1. Overview

Item Air cylinder This

controller

Position check upon power on

Determined using a reed switch or other external detection sensor.

Immediately after the power has been turned on, the current position is indeterminable because no mechanical coordinates are stored in the controller. After the power is turned on, therefore, a home return command must always be issued to establish coordinates.

[1] The actuator moves toward the mechanical end on the

motor side at the home return speed. [2] The actuator contacts the mechanical end and reverses its

direction, moves to the home position, and then pauses. (Note) Make sure no obstacles are present in the home return

path.

[1]

[2]

Home

position

Power

position

1. Overview

1.4 Meaning of the Model Number

PM: Pulse motor

Blank: No option B: With brake NM: Reversed-home

specification

FT: Foot bracket (Specified

Blank: No cable P: 1 m S: 3 m M: 5 m X: Length specification

(Example) X08 = 8 m

R: Robot cable specification

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

NP: PIO-NPN specification PN: PIO-PNP specification SE: SIO specification

16: 16 mm 12: 12 mm 8: 8 mm 6: 6 mm 4: 4 mm 3: 3 mm

<Type>

Slider type

x SA6C x SA7C

Rod type

x RA6C x RA7C x RGS6C x RGS7C x RGD6C x RGD7C

I: Incremental

ERC2-SA6C-I-PM-12-300-SE-S-NM

1. Overview

1.5 Specifications

(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 payload capacity is based on operation at the rated acceleration. In the case of a guide type, find the applicable payload

capacity in the above table and subtract the weight of the guide to obtain the effective payload capacity.

Model

Stroke (mm) and maximum speed (mm/sec) (Note 1)

Payload capacity (Note

Rated acceleration

Horizontal

Vertical Horizontal Vertical

Slider type

Rod type

1. Overview

1.5.1 Correlation Diagrams of Speed and Payload Capacity – Slider Type

(Note) In the above graphs, the number after each type name indicates the lead.

Horizontal installation Ve

rtical installation

High-speed type

Load capacity (kg)

Speed (mm/sec)

Medium-speed type Low-speed type

Load capacity (kg)

Speed (mm/sec)

Speed (mm/sec) Speed (mm/sec)

Load capacity (kg)

1. Overview

1.5.2 Correlation Diagrams of Speed and Payload Capacity – Rod Type

(Note) In the above graphs, the number after each type name indicates the lead.

Horizontal installation Ve

rtical installation

High-speed type

Load capacity (kg)

Speed (mm/sec)

Medium-speed type

Low-speed type

Load capacity (kg)

Speed (mm/sec)

Speed (mm/sec) Speed (mm/sec)

Load capacity (kg)

1. Overview

Load Applied to the Actuator

(1) Slider type

x 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 overhang length and payload capacity.

x If the slider is used in an overhang application with the load overhanging 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

x Keep the load applied to the rod below the value specified in the catalog. x Make sure the center of the rod axis corresponds to the moving direction of the load.

x Application of lateral load may cause an actuator damage or breakdown. x If the rod is to be subjected to lateral load, provide a guide or other support in

the moving direction of the load.

x Do not apply rotating torque to the rod (slide shaft).

* It will result in internal damages.

When tightening the nut at the end of the rod, secure the rod using a wrench of size 13 (RA6C type) or 17 (RA7C type).

1.5.3 The sound pressure level of this product does not exceed 70 dB.

1. Overview

1.6 Warranty

1 Warranty Period

One of the following periods, whichever is shorter:

y 18 months after shipment from our company y 12 months after delivery to the specified location

2 Scope of Warranty

Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge:

(1) The breakdown or problem in question pertains to our product as delivered by us or our authorized

dealer.

(2) The breakdown or problem in question occurred during the warranty period.

(3) The breakdown or problem in question occurred while the product was in use for an appropriate

purpose under the conditions and environment of use specified in the operation manual and catalog.

(4) The breakdown of problem in question was caused by a specification defect or problem, or by a

quality issue with our product.

Note that breakdowns due to any of the following reasons are excluded from the scope of warranty:

[1] Anything other than our product [2] Modification or repair performed by a party other than us (unless we have approved such

modification or repair)

[3] Anything that could not be easily predicted with the level of science and technology available at

the time of shipment from our company [4] A natural disaster, man-made disaster, incident or accident for which we are not liable [5] Natural fading of paint or other symptoms of aging [6] Wear, depletion or other expected result of use [7] Operation noise, vibration or other subjective sensation not affecting function or maintenance

Note that the warranty only covers our product as delivered and that any secondary loss arising from a breakdown of our product is excluded from the scope of warranty.

3 Honoring the Warranty

As a rule, the product must be brought to us for repair under warranty.

4 Limited Liability

(1) We shall assume no liability for any special damage, consequential loss or passive loss such as a

loss of expected profit arising from or in connection with our product.

(2) We shall not be liable for any program or control method created by the customer to operate our

product or for the result of such program or control method.

5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and

Applications

(1) If our product is combined with another product or any system, device, etc., used by the customer,

the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc. In such a case we will not be liable for the conformance of our product with the applicable standards, etc.

(2) Our product is for general industrial use. It is not intended or designed for the applications specified

below, which require a high level of safety. Accordingly, as a rule our product cannot be used in these applications. Contact us if you must use our product for any of these applications:

[1] Medical equipment pertaining to maintenance or management of human life or health [2] A mechanism or mechanical equipment intended to move or transport people (such as a

vehicle, railway facility or aviation facility) [3] Important safety parts of mechanical equipment (such as safety devices) [4] Equipment used to handle cultural assets, art or other irreplaceable items

(3) Contact us at the earliest opportunity if our product is to be used in any condition or environment that

differs from what is specified in the catalog or operation manual.

6 Other Items Excluded from Warranty

The price of the product delivered to you does not include expenses associated with programming, the dispatch of engineers, etc. Accordingly, a separate fee will be charged in the following cases even during the warranty period:

[1] Guidance for installation/adjustment and witnessing of test operation [2] Maintenance and inspection [3] Technical guidance and education on operating/wiring methods, etc. [4] Technical guidance and education on programming and other items related to programs

1. Overview

1.7 Transportation and Handling

1.7.1 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.

x If the box is heavy, one person should not carry it by himself. x Place the box in a level surface. x Do not step on the box. x 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.

1.7.2 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.

x 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.

x Do not exert excessive force on each part of the actuator. In particular, pay attention to the motor cover and

cables.

x When unpacking, exercise due caution not to let the actuator drop and sustain damage to its mechanism. x 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. Overview

1.8 Installation Environment and Noise Elimination

Pay due attention to the installation environment of the controller.

1.8.1 Installation Environment

The installation environment must satisfy the following conditions:

No. Use enviro

nment/condition

[1] Not exposed to direct sunlight.

[2]

The actuator is not subject to irradiated heat from a large heat source, such as a heat treatment furnace.

[3]

Ambient temperature of 0 to 40qC.

[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.

1.8.2 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 60qC for a short period of time. If the storage period will extend beyond one month, however, keep the storage temperature below 50qC.

1. Overview

Actuator with

integrated

controller

Other

equipment

Other

equipment

Actuator with

integrated

controller

1.8.3 Power Supply

The control/motor-drive power supply specification is 24 VDC r 10% (2 A max).

1.8.4 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

or larger.

Class D grounding Good Avoid this

grounding method.

[2] Precautions regarding wiring method

Wire extension cables separately from high-power lines for power circuits, etc. (Do not bundle them together or place them in the same cable duct.)

1. Overview

Diode

(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.

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.

m Point

Install a surge absorber to each coil over a minimum wiring length. Installing a surge absorber to the terminal block or other part will be less effective because of a longer distance from the coil.

Surge absorber

1. Overview

1.9 Cabling

x When storing a extension cable in a moving wiring duct, use a robot cable. x 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.

x 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.

1. Overview

Prohibitions/Notes on Handling 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.

2. Do not let the cable bend, kink or twist. 3. Do not pull the cable with a strong force.

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.

5. When fixing the cable, provide a moderate slack

and do not tension it too tight.

Steel band (piano wire)

Bundle loosely.

Use a curly

cable.

Do not use a spiral tube where the cable flexes fre

uently.

1. Overview

</59 </39

Cable

Cable track

Power line

Signal lines (flat cable, etc.)

Duct

7. Notes on use of cable tracks

z Do not let the cable get tangled or kinked in a cable track or flexible tube. When bundling the cable, keep

a certain degree of flexibility (so that the cable will not become too taut when bent).

z Do not cause the cables to occupy more

than 60% of the space in the cable track.

z Do not store signal lines in the same cable

duct as high-power lines.

z Always use a

robot cable for each extension

Bending radius (r)

z Use a cable track with a bending

radius (r) of 50 mm or more.

Robot cable

1. Overview

LED

Non-motor end

Motor end

Right

Left

Cou

ling bol

Front bracket

Rear bracke

Motor bracket

Motor cover Cable

Rod

Frame

Rod end bracket

Top

Bottom

Non-motor

Screw cover Coup

ling bolt

Right

Left

Motor end

Side cove

LED

Top

Bottom

ont bracket

Slider

earbracket

Motor bracket

Rear cover

Base

Motor cover

Cable

2. Installation

2.1 Name of Each Part

2.1.1 Slider Type (SA6C/SA7C)

2.1.2 Rod Type (RA6C/RA7C)

Rear cover

2. Installation

2.1.3 (1) Rod Type with a Single Guide (RGS6C/RGS7C)

(2) Rod Type with Double Guides (RGD6C/RGD7C)

Non-motor end

Coupling bolt

Right

Left

Motor end

LED

Top

Bottom

Cable

Motor cover

Rod

Frame

earbrac

Motor bracket

Rear cover

Guide bracket Guide bearing

Guide rod

Non-motor end

Coupling bolt

Right

Left

Motor end

LED

Top

Bottom

Cable Motor cover

Rod

Frame

Rear bracke

Motor bracket

Rear cover

Mounting bracket

Guide bearing

Guide rod

Guide bracket

2. Installation

2.2 Installation

2.2.1 Slider Type

z 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 precision is required, install the actuator by using these surfaces as references.

(Note) Reduced flatness due to installation of an overhang 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.

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

Slider type

2. Installation

Hex cap bolt

Hole in flange

2.2.2 Rod Type

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

z 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.

Flange tightening bolts

Model Nominal thread size Tightening torque

RA6C M5 3.4 Nm (0.35 kgfm)

RA7C M6 5.4 Nm (0.55 kgfm)

z Affixing through holes in a flange

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

RGD6C M5

Steel bolt-bearing surface: 7.3 N-m

Aluminum bolt-bearing surface: 3.4 N-m

RGD7C

Steel bolt-bearing surface: 12.3 N-m

Aluminum bolt-bearing surface: 5.4 N-m

Hex cap bolt

2. Installation

z 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 RA6C

RGS6C

RGD6C

M6 5.4 Nm (0.55 kgf-m)

RA7C

RGS7C

RGD7C

M8 11.5 Nm (1.17 kgf-m)

2. Installation

2.2.3 Installing the Load

z 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

SA6C, SA7C 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

SA6C, SA7C

5, H10, depth 10 mm

2. Installation

z 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 e

nd bracket RA6C M8, length 18 mm RA7C M10, length 21 mm

Note) Apply a spanner wrench 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. RA6C: Width across flats 13 mm RA7C: Width across flats 17 mm

z Rod type with a guide(s)

Model Nominal thread size

RGS6C M5

RGD6C

M5 RGS7C M6 RGD7C M6

Tightening torque

Nominal

thread size

Bolt bearing surface: steel

Bolt bearing surface:

aluminum

7.3 Nxm (0.74 kgf-m) 3.4 Nxm (0.35 kgf-m)

12.3 Nxm (1.26 kgf-m) 5.4 Nxm (0.55 kgf-m)

Double guides

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

Single guide

2. Installation

3. Electrical Specifications

3.1 Controller

Specification item Description

Number of controlled axes 1 axis/unit

Supply voltage

24 VDC r10%

Supply current 2 A max.

Control method Weak field-magnet vector control

Positioning command

Position number specification, numerical specification, simple numerical/position number specification

Position number Maximum 64 points

Backup memory

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

PIO None

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

Method Magnetic type

Signals 0 to 5 V, phases A/B, incremental

Encoder

Resolution 200 pul

ses/rev (multiplied by 4 in an external circuit)

Communication RS485 1 channel (terminated externally)

Communication protocol Modbus/RTU, Modbus/ASCII

Electromagnetic brake

A drive circuit is provided. 24 VDC r 10%, 0.15 A max.

Electromagnetic brake Release

The user must provide a selector switch. (Current consumption: 0.15 A max.)

Extension cable length 10 m or less

Communication cable length 100 m max. in total cable length

Isolation strength

500 VDC, 10 M:

Environment

Ambient operating temperature

0 to 40qC

Ambient operating humidity

85%RH or less (non-condensing)

Operating ambience Free from corrosive gases, flammable gases, oil mist, and dust.

Storage temperature

-10 to 65qC (non-freezing)

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

Vibration resistance

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

Protection class IP20

Weight Approx. 25 g

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

3. Electrical Specifications

3.2 Input/Output Interfaces

Connector pin No. Signal name Description

1 SGA

2 SGB

3 5V

4 GND

RS485 serial communication

5 24V Control power, 24 V

6 BKR Brake release (The brake is released when 24 V, 150 mA is supplied.)

7 MPI Motor drive power, 24 V

8 GND Control power, 0 V

9 Shield

J.S.T. Mfg. Receptacle housing Pin contact

3. Electrical Specifications

Orange

Blue

Brown

Green

Red

Gray

Yellow

Black

Shield

Signal name Wire color Wire

Control power

Brake

Shield

Shielded wire

Blue

Yellow

Red

Black

Purple

Gray

Green

Orange

Shielded wire

Standard cable

Robot cable

3.2.1 Extension Cable

This cable is a standard accessory of the controller.

(1) Power & I/O cable

(Model number: CB-ERC2-PWBIO***/CB-ERC2-PWBIO***-RB)

(Note) CB-ERC2-PWBIO***-RB indicates a robot cable.

(2) Network connection cable (Model number: CB-ERC2-CTL001)

* This cable comes with the following parts:

x e-con connector x 1 x e-con connector (with terminal resistor) x 1 x 4-way junction x 1

CN2 Manufacturer: J.S.T. Mfg. Housing: Contact:

Kaneko Cord

Connector cover

No connector at cable end

Manufacturer: J.S.T. Mfg. Model: V0.5-3

Model number nameplate

CN1 Manufacturer: J.S.T. Mfg. Plug housing:

YLP-09V X1

Socket contact:

SYF-01T-P0.5A X9

Orange

Blue

Green

Orange

Blue

Green

Wire:

CN1 Manufacturer: J.S.T. Mfg. Plug housing: PALR-04VF X1 Socket contact: SPAL-001T-P0.5 X4

CN2 Manufacturer: AMP e-CON connector, 4-pin plug (green) Model: 4-7473562-4

Wire Color Signal name Signal name Color Wire

Orange

Blue Brown Green

Wire Color Signal name

(Note 1) Twisted pair (Note 2) Ground

Note 2

Note 1

3. Electrical Specifications

3.3 SIO Converter (Optional)

Model number: RCB-TU-SIO-A (Vertical installation)

RCB-TU-SIO-B (Horizontal installation)

This unit is a RS232C-RS485 converter. When multiple controllers are linked together, you can use the SIO converter to perform movement operations and edit parameters for all axes at the same time by connecting a teaching pendant to the mini-DIN, 8-pin connector on the converter.

z Explanation of functions

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

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

EMG1, EMG2

24V

0V FG

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 extension cable. “B” on the right side connects to SGB (wire color: orange/black 1) in the extension cable. (Note) Be sure to use twisted pair wires for the above two lines (SGA/SGB).

[3] Link connectors (J4, J5)

e-con connection ports for linking the controller. These ports accept an optional link cable (CB-RCBCTL002) directly. Note that J4 and J5 provide connections for two axes only. To connect three or more axes, use the terminal block explained in [2].

[2] Link-connection

terminal block (TB1)

[1] Power/emergency-stop

terminal block (TB2)

[7] Monitor LEDs

[4] D-sub, 9-pin connector

[6] PORT switch

[5] Mini DIN, 8-pin connector

[3] Link connectors (J4, J5)

3. Electrical Specifications

Signal

D-sub 9-pin, female

D-sub 9-pin

PC: Female PLC: Male

[4] D-sub, 9-pin connector (RS232C)

A connection port with the PLC’s communication module. You can also connect a PC here. For the communication cable, use a RS232C crossed cable as explained below.

[5] Mini DIN, 8-pin connector (RS485)

A connection port with the teaching pendant. For the communication cable, use the cable (with RS232C/RS485 converter) supplied with the PC software (RCM-101-MW).

[6] PORT switch

A switch for enabling/disabling the mini-DIN connector. Set this switch to ON when a device is connected to the mini-DIN connector, or OFF when no device is connected.

[7] Monitor LEDs

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

(Reference) Connection drawing of a RS232C crossed cable (generic brand)

SIO converter end

3. Electrical Specifications

4. Wiring

4.1 Basic Configuration with SIO Converter

Connect a teaching pendant, PC or PLC using a SIO converter (for RS232C/RS485 conversion), as shown below.

Caution: Do not connect any device to the mini-DIN connector and D-sub connector at the same

time. If a device is connected to these connectors at the same time, a communication error (message level) will occur.

PC software RS232C type <RCM-101-MW> USB type <RCM-101-USB>

Optional

Teaching pendant

<RCM-T>

Optional

Cable length: 5 m

ERC2-SE actuator

RS232C crossed cable (generic brand)

*1 Connect the communication line from the actuator

to either TB1 or J4 (J5) on the SIO converter, as shown below.

*2 The customer must produce an appropriate cable.

SIO converter

Vertical <RCC-TU-SIO-A> Horizontal <RCC-TU-SIO-B>

e-CON connector

Network connection

cable

J.S.T. Mfg.

24-VDC control power, motor power, brake signal, ground, shield

Power & I/O cable

J.S.T. Mfg.

(Female) (Female)

(Female)

Supplied cable

(Male)

4. Wiring

z Connection diagram

An example of serial communication connection, including an emergency stop circuit, is shown below. Emergency stop is actuated by means of cutting off the motor drive power.

*1 The wire colors for standard cables and robot cables are

different. The colors in parentheses are for robot cables.

ERC2-SE actuator

Serial communication

Orange (Blue)

Blue (Yellow)

Brown (Red)

Green (Black)

Gray (Gray)

Red (Purple)

Black (Orange)

Yellow (Green)

Teaching pendant

EMG

pushbutton

SIO converter

TP connector

EMG reset

switch

EMG

pushbutton

Terminal block

Power supply

The brake is released when the contacts are closed.

I/F connector

Brake release (24 V, 150 mA)

Control power, 24 V

Motor drive power, 24 V

Shield

4. Wiring

4.1.1 SIO Communication Connection Using a Relay Terminal Block

* The emergency stop circuit is the same as illustrated on the previous page.

(Note 1) If the total length of the communication cable is 10 m or longer and you experience

communication errors, connect a terminal resistor 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.

Teaching pendant PC, PLC

Relay terminal

block

Actuator 1

Actuator 2

Actuator 3

One-pair shielded cable (Fabricated by the customer)

Terminal resistor

1/2W, 220 :

SIO converter

Actuator 16

J.S.T. Mfg.

Power & I/O cable

J.S.T. Mfg.

24-VDC control power, motor power, brake signal, ground, shield

(

Fabricated by the customer)

4. Wiring

4.1.2 SIO Communication Connection Using a 4-Way Junction

(Note 1) If the total length of the communication cable is 10 m or longer and you experience

communication errors, connect a terminal resistor to the last axis.

(Note 2) If the actuators use different power supplies, align 0 [V] on all power supplies. (Note 3) The gateway unit power must be the same as 0 V of the ERC2 control power. (Note 4) Connect the shielded wire of each axis to FG. (Note 5) If the overall length of link cable exceeds 30 m, use wire of 22AWG or larger size.

Teaching

pendant

Actuator 1

Actuator 2

Actuator 3

Actuator 16

J.S.T. Mfg.

24-VDC control power, motor power, brake signal, ground, shield

e-CON connector

Fabricated by the customer

Network connection cable

Power & I/O cable

PC, PLC

4. Wiring

4.1.3 Address Assignment

If multiple axes are connected, a slave number must be assigned to each axis so that the host can recognize the corresponding actuator. Assign addresses in the setting screen of the teaching pendant or PC.

z Overview of operation on the PC

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

the cursor to Assign Address (N) and click the mouse o [5] Enter an appropriate number in the address table.

z Overview of operation on the teaching pendant RCM-T

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

an appropriate address and press the ENTER key o [4] Enter “2” under Adjustment No. and press the ENTER key.

z Overview of operation on the simple teaching pendant RCM-E

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

o [3] Enter an appropriate address and press the ENTER key o [4] Enter “2” under Adjustment No. and press the ENTER key.

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

Caution: 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.

4. Wiring

4.2 Configuration Using a Gateway Unit

4.2.1 SIO Communication Connection Using a Relay Terminal Block

(Note 1) If the total length of the communication cable is 10 m or longer and you experience

communication errors, connect a terminal resistor to the last axis.

PC software RS232C type <RCM-101-MW> USB type <RCM-101-USB> Optional

Teaching

pendant

Relay terminal

block

Actuator 1

Actuator 2

Actuator 3

One-pair shielded cable (Fabricated by the customer)

Terminal resistor

1/2W, 220 :

Actuator 16

Gateway

unit

J.S.T. Mfg.

24-VDC control power, motor power, brake signal, ground, shield

Fabricated by the customer

Power & I/O cable

4.2.2 SIO Communication Connection Using a 4-Way Junction

(Note 1) If the total length of the communication cable is 10 m or longer and you experience

communication errors, connect a terminal resistor to the last axis.

PC software RS232C type <RCM-101-MW> USB type <RCM-101-USB> Optional

Teaching

pendant

Actuator 1

Actuator 2

Actuator 3

Actuator 16

Gateway

unit

J.S.T. Mfg.

4-way junction

e-CON connector

24-VDC control power, motor power, brake signal, ground, shield

Fabricated by the customer

Network connection cable

Power & I/O cable

4. Wiring

4.2.3 Connecting an Emergency Stop Circuit, Etc.

Emergency stop is actuated by means of cutting off the motor drive power.

*1 The wire colors for standard cables and robot cables are

different. The colors in parentheses are for robot cables.

(Note 1) The gateway unit power must be the same as 0 V of the ERC2 control power.

Serial communication

ERC2-SE actuator

Teaching pendant

EMG

pushbutton

Gateway unit

TP connector

EMG reset

switch

EMG

pushbutton

Power supply

The brake is released when the contacts are closed.

I/F connector

Brake release (24 V, 150 mA)

Control power, 24 V

Motor drive power, 24 V

Shield

Gateway

owe

Port switch

Orange (Blue)

Blue (Yellow)

Brown (Red)

Green (Black)

Gray (Gray)

Red (Purple)

Black (Orange)

Yellow (Green)

4. Wiring

5. Explanation of Operating Functions

ERC2-SE actuators support two operation modes: [1] “position number specification mode” in which the actuator is operated by specifying position numbers, and [2] “numerical specification mode” in which the actuator is operated by directly specifying values relating to the intended operation. To move the actuator to a specified position in the “position number specification mode,” basically a position table must be created in advance by entering the target position in the “Position” field. The target position can be specified as an absolute distance from the home (absolute mode), or as an incremental travel from the current position (incremental mode). Once the target position is entered, other fields will be automatically populated with the defaults set by the applicable parameters. The defaults set in the respective fields vary depending on the actuator characteristics. Additionally, ERC2-SE actuators can be operated over a field network or via RS232C serial communication. Accordingly, also refer to the operation manual for your gateway unit as well as the Operation Manual for Serial Communication Protocol.

5. Explanation of Operating Functions

Position Speed Acceleration Deceleration Push Threshold

Positioning

band

Zone+ Zone–

Acceleration/

deceleration

mode

Incremental

Command

mode

Standstill

mode

Comment

5.1 Description of Position Table

Create a position table using the PC software or teaching pendant. Refer to the operation manual for the PC software or teaching pendant you are using. This section explains the position table by using the PC software screen as an example. (The displayed items are different on the teaching pendant.)

(1) No.

x Indicate the position data number.

(2) Position

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

Absolute mode: Enter the distance to the target actuator position

from the actuator’s home.

Incremental mode: Enter the distance to the target actuator position

from the current position by assuming a movement by constant pitch feed.

(3) Speed

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

The default value varies depending on the actuator type.

Absolute mode The target is 30 mm from the home. Incremental mode +10 mm from the current position. Incremental mode -10 mm from the current position.

Position

* On the teaching pendant screen, this sign

indicates that the position is specified in the incremental mode.

5. Explanation of Operating Functions

(4) Acceleration/Deceleration

x Enter the acceleration/deceleration at which the actuator will be

moved, in [G]. Basically, you should set values within the rated range specified in the catalog. The input range is greater than the rated range in the catalog, in order to accommodate situations where you want to “shorten the tact time when the load is much smaller than the rated transferring mass.” If the load vibrates during acceleration/deceleration and causes problem, decrease the set values.

Increasing the set value makes acceleration/deceleration quicker, while decreasing the set value makes acceleration/deceleration more gradual.

Caution: When setting the speed and acceleration/deceleration, refer to 1.5, “Specifications” and

enter appropriate values that will prevent the actuator from receiving excessive impact or vibration, by considering the installation conditions and shape of the load. Increasing the speed and acceleration/deceleration changes the transferring mass significantly, and the actuator characteristics also vary from one model to another. Therefore, consult IAI’s Sales Engineering Section for the maximum limits that can be entered in your specific application.

(5) Push

x Select “positioning operation” or “push & hold operation.”

The factory setting is “0.” 0: Normal po

sitioning operation

Other than 0: Push & hold operation (The set value defines the

current-limiting value.)

(6) Threshold

x This field is not used for this controller.

The factory setting is “0.”

(7) Positioning band

x The meaning of the positioning band varies between “positioning

operation” and “push & hold operation.”

“Positioning operation” The set value defines the distance before the target position at which the position complete signal will turn ON. Increasing the positioning band quickens the start of the next operation in the sequence, meaning that the tact time can be reduced. Set an appropriate value based on the overall balance of your system.

Speed

cceleration Deceleration

Time

Starting

position

Target

position

The position complete signal turns ON here.

Positioning band

Target position

5. Explanation of Operating Functions

“Push & hold operation” The set value defines the maximum distance the actuator will push the work part in the push & hold mode upon reaching the target position. Consider the mechanical variations of the work part and set an appropriate positioning band so that positioning will not complete before the actuator contacts the work part.

(8) Zone+/–

x Define the zone in which the zone output signal turns ON.

For added flexibility, different values can be set for each target position.

[Setting example]

The position complete signal turns ON here, because the actuator has contacted the load and the controller has determined that the push & hold operation has completed.

Push speed

Positioning band (Maximum push distance)

Target position

Position Zone+ Zone– Comment

Movement command to position No.

Zone output signal

Home

Target position

+ limit

Movement command to position No.

Zone output signal

Speed

+ limit

- limit

5. Explanation of Operating Functions

(9) Acceleration/deceleration

mode

x This field is not used for this controller.

The factory setting is “0.”

(10) Incremental

x This setting defines whether to use the absolute mode or incremental

mode. The factory setting is “0.” 0: Absolute mode 1: Incremental mode

(11) Command mode

x This field is not used for this controller.

The factory setting is “0.”

(12) Standstill mode

x This field is not used for this controller.

The factory setting is “0.” The power-saving mode to be applied while the actuator is standing by is set by parameter No. 53. The full servo control mode can be selected by setting “4” in this field.

Full servo control mode

The pulse motor is servo-controlled to reduce the holding current (standstill current that flows after completion of positioning). Although the exact degree of current reduction varies depending on the actuator model, load condition, etc., the holding current decreases to approx. one-half to one-fourth. Since the servo remains on, no position deviation occurs. The actual holding current can be checked in the current monitor screen of the PC software. To enable this mode, set “4” in this field.

5. Explanation of Operating Functions

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 table. Determine the current-limiting value (%) from the push force to be applied to the work part at standstill. The graphs below illustrate the relationship of push force at standstill and current-limiting value for each actuator type:

z Slider type (1) SA6C type (2

) SA7C type

Low-speed type Low-speed type

(Lead: 3 mm) (Lead:

4 mm)

Medium-speed type Medium-spee

d type

(Lead: 6 mm) (Lead: 8 mm)

High-speed type High-spee

d type

(Lead: 12 mm) (L

ead: 16 mm)

Caution: The precision 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%.

Push force (N)

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

Push force (N)

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

5. Explanation of Operating Functions

z Rod type (1) RA6C type (2

) RA7C type

Low-speed type Low-speed

type

(Lead: 3 mm) (Lead:

4 mm)

Medium-speed type Medium-spee

d type

(Lead: 6 mm) (Lead: 8 mm)

High-speed type High-spee

d type

(Lead: 12 mm) (L

ead: 16 mm)

Caution: The precision 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%.

Push force (N)

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

Push force (N)

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

5. Explanation of Operating Functions

5.2 Data Set in the Numerical Specification Mode

When the actuator is operated in the numerical specification mode, specify data relating to the intended operation (target position, speed, acceleration/deceleration, positioning band, current-limiting value during push & hold operation, etc.) directly. Take note that the position table may or may not be required depending on the operation mode. For details, refer to the Operation Manual for Gateway Unit and the Operation Manual for Serial Communication Protocol.

5.3 Explanation of Functions

The table below lists the key functions available on ERC2-SE actuators in the position number specification mode and the numerical specification mode, respectively.

5. Explanation of Operating Functions

ERC2-SE Function List

{: Direct control, ': Indirect control, X: Not available

Position number specification mode Numerical specification mode

DeviceNet gateway CC-Link gateway

Serial

communication

Gateway

Position number

specification mode

Serial

communication

Direct numerical

specification mode

Command

specification mode

Position data limited

mode

Normal positioning

mode

Push & hold mode

Command

specification mode

Home return

operation

{ { { { { { { { {

Positioning

operation

' Specify a

position number

in the position

table.

' Same as on the

left

{ Specify position

data directly.

{ Specify position

data directly.

{

Specify position

data directly.{Specify a

position number

in the position

table.

{ Specify position

data directly.

{ Specify position

data directly.

{ Specify position

data directly.

{

Specify position

data directly.

{ Specify a position

number in the

position table.

Speed setting

' Set in the

position table.

' Same as on the

left

{ Specify directly

as a numerical

value.

{ Specify directly as

a numerical value.

' Set in the

position table.

' Set using a

parameter.

{ Specify directly as

a numerical

value.

{ Specify directly as

a numerical value.

' Set in the

position table.

Acceleration/

deceleration setting

' Set acceleration

and deceleration

differently in the

position table.

' Same as on the

left

{

Specify an

acceleration/

deceleration

directly as a

numerical value.

{

Specify an

acceleration/

deceleration directly

as a numerical

value.

' Set

acceleration

and

deceleration

separately in

the position

table.

{

Set an

acceleration/

deceleration using

a parameter.

{

Specify an

acceleration/

deceleration

directly as a

numerical value.

{

Specify an

acceleration/

deceleration directly

as a numerical value.

' Set in the

position table.

Operation by setting

acceleration and

deceleration

differently

' Set acceleration

and deceleration

differently in the

position table.

' Same as on the

left

{

Acceleration/

deceleration data is

accepted when

positioning is started.

To specify a

deceleration different

from an acceleration,

therefore, change the

acceleration/deceleratio

n data while the

actuator is moving, and

then restart the

operation.

{

Acceleration/

deceleration data is

accepted when

positioning is started. To

specify a deceleration

different from an

acceleration, therefore,

change the

acceleration/deceleration

data while the actuator is

moving, and then restart

the operation.

' Set

acceleration

and

deceleration

separately in

the position

table.

X Since an

acceleration/deceler

ation is set by a

single parameter,

acceleration and

deceleration cannot

be set differently.

{

Acceleration/

deceleration data is

accepted when

positioning is started. To

specify a deceleration

different from an

acceleration, therefore,

change the

acceleration/deceleratio

n data while the actuator

is moving, and then

restart the operation.

{

Acceleration/

deceleration data is

accepted when positioning

is started. To specify a

deceleration different from

an acceleration, therefore,

change the

acceleration/deceleration

data while the actuator is

moving, and then restart

the operation.

' Set acceleration

and deceleration

separately in the

position table.

Pitch (incremental)

feed

' Set in the

position table.

' Same as on the

left

{ Change bit 2 of

the CTLF control

flag to “1” to perform

incremental

operation.

No direct command is

available to process a

pitch feed request.

Program the host PLC to

add or subtract a constant

travel to/from the current

position and then issue a

position command.

' Set in the

position table.

No direct command

is available to process a

pitch feed request.

Program the host PLC

to add or subtract a

constant travel to/from

the current position and

then issue a position

command.

No direct command is

available to process a

pitch feed request.

Program the host PLC to

add or subtract a

constant travel to/from

the current position and

then issue a position

command.

No direct command is

available to process a

pitch feed request.

Program the host PLC to

add or subtract a constant

travel to/from the current

position and then issue a

position command.

' Set in the

position table.

Push & hold

operation

' Set in the

position table.

' Same as on the

left

{

{ Specify position

data directly.

' Set in the

position table.

X X

{

' Set in the

position table.

Speed change

during movement

' Combine two or

more position

numbers.

' Same as on the

left

{

Speed data is

accepted when

positioning is started.

To change the speed

during movement,

therefore, change the

speed while the

actuator is moving, and

then restart the

operation.

{

Speed data is

accepted when

positioning is started. To

change the speed during

movement, therefore,

change the speed while

the actuator is moving,

and then restart the

operation.

' Combine two or

more position

numbers.

{

Speed data is

accepted when

positioning is started. To

change the speed during

movement, therefore,

change the speed while

the actuator is moving,

and then restart the

operation.

{

Speed data is accepted

when positioning is

started. To change the

speed during movement,

therefore, change the

speed while the actuator is

moving, and then restart

the operation.

' Combine two or

more position

numbers.

Pause

{ { { { { { { { {

Zone signal { Zone signals are

set in the position

table or using user

parameters.

PZONE, ZONE1

and ZONE2 can be

output.

{ Zone signals are

set using user

parameters. ZONE1

and ZONE2 can be

output.

{ Zone signals are

set using user

parameters. ZONE1

and ZONE2 can be

output.

This function is not

available for simple

numerical

specification axes

Positioner operation: O(Depending on the

PIO pattern)

X X

This function is not

available for simple

numerical specification

axes.

Positioner operation: O

(Depending on the PIO

pattern)

Power-saving mode

{

The “full servo

control” power-saving

mode can be selected

using parameter No. 53.

(The automatic servo-

off mode cannot be

selected.)

{

Same as on the left

{

Same as on the left

{

Same as on the left

{

Same as on the

left

{

Same as on the left

{

Same as on the left

{

Same as on the left

{

Same as on the left

Position table Required Required Not required Not required Required Not required Required Required Required

5. Explanation of Operating Functions

5.3.1 Control Signals and Control Data

To operate the actuator via serial communication, the internal 16-bit memory (Modbus registers and statuses) of the controller must be written/read. The key signals and symbols used in these operations are explained below. For details, refer to the Operation Manual for Serial Communication Protocol.

(1) Controller input signals

(PLC o Controller)

Bit

address

Bit

position

Signal

symbol

Signal name Description

15 - - -

0401H 14 SFTY

Safety speed command

When this bit is “0,” the safety speed set by the parameter is disabled. When the bit is “1,” the safety speed is enabled.

13 - - -

0403H 12 SON

Servo ON command

The servo is off when this bit is “0” and on when the bit is “1.”

- - -

0407H 8 RES Alarm reset

The “0” status of this bit indicates a normal condition. Present alarms will be reset at the “0” o “1” edge of this bit.

7 - - -

6 - - -

040AH 5 STP Pause command

The “0” status of this bit indicates a normal condition. When this bit changes to “1,” the actuator will pause (decelerate to a stop).

040BH 4 HOME

Home return command

Home return operation will be performed at the “0” o “1” edge of this bit.

040CH 3 CSTP Positioning start

The “0” status of this bit indicates a normal condition. The actuator will start moving to the target position specified by the applicable position number at the “0” o “1” edge of this bit.

Device control register DRG1

Address 0D00H

[Common]

- - -

(Note) The meanings of [Common], [POS specification] and [Numerical specification] in the “Register” field are

explained below: x [Common]: The re

gister is used in both the position number specification mode and the

numerical specification mode.

x [POS specification]: The register is used in the position number specification mode. x [Numerical specification]: The register is used in the numerical specification mode.

5. Explanation of Operating Functions

(PLC o Controller)

Bit

address

Bit

position

Signal

symbol

Signal name Description

- - -

043AH 5 PC32 -

043BH 4 PC16 -

043CH 3 PC8 -

043DH 2 PC4 -

043EH 1 PC2 -

Position number specification register

POSR

Address

0D03H

[POS specification]

043FH 0 PC1 -

Specify

a command position number using a 6-bit binary code. Positioning operation will start when the positioning start signal bit CSTR is changed to “1.”

- - -

- 5 PC32 -

- 4 PC16 -

- 3 PC8 -

- 2 PC4 -

- 1 PC2 -

Position number specification register

POSR

Address

9800H

[POS specification]

- 0 PC1 -

This

register is the same as the one explained above, except that with this register, positioning operation will start the moment a command position number is written. There is no need to change the positioning start signal bit CSTR to “1.”

5. Explanation of Operating Functions

(PLC o Controller)

Description

PCMD Position data specification

[Numerical specification]

INP Positioning band specification

[Numerical specification]

VCMD Speed specification

[Numerical specification]

CMD

cceleration/

deceleration

[Numerical specification]

Upper

Lower

Sign

Signed 32-bit integer (unit: 0.01 mm) Setting range: FFF0BBC1H to 000F423FH (-999999 to 999999) x A negative value is indicated by a 2’s complement. Accordingly, the most

significant bit becomes “1.” Positioning operation will start when the lower word (9901H) of this register is rewritten.

Upper

Lower

Upper

Lower

32-bit integer (unit: 0.01 mm) Setting range: 0H to 000F423FH (0 to 999999) In positioning operation, this register sets a band within which a completion of positioning is detected. In push & motion operation (the push & motion operation must be specified using the CTLF flag), this register sets a push band.

32-bit integer (unit: 0.01 mm/sec) Setting range: 0H to 000F423FH (0to 999999) This register specifies a moving speed. Movement will start when the lower word (9905H) of this register is rewritten.

16-bit integer (unit: 0.01G), setting range: 0H to 012CH (0 to 300) If a value exceeding the default acceleration/deceleration is set in parameter No. 9, an alarm will generate the moment the actuator starts moving. Movement will start when this register is rewritten.

5. Explanation of Operating Functions

(PLC o Controller)

(Note) Set in a range of 20% to 70% (33H to B3H) if the actuator imposes limitations.

scription

Currentlimiting value during push & hold operation [Numerical specification]

CTLF Control flag

[Numerical specification]

16-bit integer (unit: %, setting range: 00H to FFH/ 0 to 100 %) (Note) Movement will start when this register is rewritten.

This flag sets a bit pattern to specify operation settings. [1] Bit 1 (b1) 0: Normal operation 1: Push & hold operation [2] Bit 2 (b2) 0: The push direction after completion of approach operation

represents the forward direction.

1: The push direction after completion of approach operation

represents the reverse direction.

[3] Bit 3 (b3) 0: Normal operation 1: Incremental operation

5. Explanation of Operating Functions

(2) Controller output signals

(Controller o PLC)

Bit

address

Bit

position

Signal

symbol

Signal name Description

0100H 15 EMGS

Emergency stop status

An emergency stop is being actuated when this bit is “1.”

0101H 14 SFTY

Safety speed enabled

The safety speed is enabled when this bit is “1.”

0102H 13 PWR Controller ready The controller is ready when this bit is “1.”

0103H 12 SV Servo ready

Operation can be performed at any time (the servo is on) when this bit is “1.”

0104H 11 PSFL

Missed work part during push & hold operation

The actuator has missed the work part during push & hold operation, when this bit is “1.”

0105H 10 ALMH

Major failure status

An alarm is present that inhibits continuation of operation, when this bit is “1.”

0106H 9 ALML

Minor failure status

An alarm is present that permits continuation of operation, when this bit is “1.”

- - -

010AH 5 STP

Pause command active

A pause command is being executed when this bit is “1.”

010BH 4 HEND

Home return completion

Home return has completed when this bit is “1.”

010CH 3 PEND Position complete

Positioning has completed when this bit is “1.”

Device status register

DSS1

Address

9005H

[Common]

- - -

0124H 11 GHMS Homing

Home return operation is currently in progress when this bit is “1.”

0123H 10 PUSH

Pushing & holding

Push & hold operation is currently in progress when this bit is “1.”

- - -

012AH 5 MOVE Moving

The actuator is moving (during home return, push & hold operation, etc.) when this bit is “1.”

Expansion device status register

DSSE

Address

9007H

[Common]

- - -

5. Explanation of Operating Functions

(Controller o PLC)

Bit

address

Bit

position

Signal

symbol

Signal name Description

- - -

0147H 8 PZONE

Position zone output

If individual zone boundaries are set in the position table, this bit will turn “1” when the current position enters the range specified by the boundaries.

- - -

014EH 1 ZONE2

Zone output 2 This bit will turn “1” when the current

position enters the range specified by the zone boundary 2 parameters.

Zone status register

ZONS

Address

9013H

[Common]

014FH 0 ZONE1

Zone output 1 This bit will turn “1” when the current

position enters the range specified by the zone boundary 1 parameters.

- - -

013AH 5 PM32

013BH 4 PM16

013CH 3 PM8

013DH 2 PM4

013EH 1 PM2

Position number status register

POSS

Address

9014H

[POS specification]

013FH 0 PM1

A completed position number is output using a 6-bit binary code.

(Controller o PLC)

PNOW Current position

[Numerical specification]

The current position is indicated by a signed 32-bit intege

(unit: 0.01 mm).

negative value is indicated by a 2’s complement. Accordingly, the most significant bit

becomes “1.”

Upper

Lower

Sign

5. Explanation of Operating Functions

5.3.2 Timings after Power On

Follow the procedure below to turn on the power after confirming that the slider or rod is not contacting a mechanical end nor the load is contacting any peripheral equipment:

[1] Cancel the emergency stop or turn on the motor drive power. [2] Supply the 24-VDC controller power.

If 24 VDC is supplied in a condition where no emergency stop is actuated, the servo will be turned on automatically in the controller.

[3] Initial setting of minimum parameter(s) required

(Example) x To change the feed speed during teaching:

Change parameter No. 35 (Safety speed).

[4] Using a PC or teaching pendant to set optimal values in the “Position,” “Speed,” “Acceleration” and

“Deceleration” fields, etc., of the position table.

Caution: When the power is turned on while an emergency stop is actuated, and then the emergency

stop is cancelled, the servo will turn on with a maximum delay of 170 msec after the cancellation of emergency stop.

Safety circuit condition

Supply of 24-VDC controller power

SV lamp

(on front panel)

Controller ready

(PWR)

Pause (STP)

Servo ON command

(SON)

Servo ready (SV)

Position complete

(PEND)

Emergency stop cancelled

Orange light illuminates for 2 seconds, and then turns off.

Green

Initial parameter

Initial condition “1”

Pause cancelled

170 msec max.

Emergency stop cancelled

170 msec max.

Servo on

5. Explanation of Operating Functions

Warning: Since a pulse motor is used as the driving motor, the excited phase will be detected when the

servo is turned on for the first time after the power on.

Accordingly, the actuator must be able to move when the servo is turned on. If the slider or rod is contacting a mechanical end or the load is contacting any peripheral equipment, the excited phase will not be detected correctly and a malfunction or excitation detection error may result. In such a case, move the actuator by hand to a position where it can move freely, before turning on the servo. If the actuator is equipped with a brake, the brake release switch must be turned on to forcibly release the brake. When operating the brake release switch, be careful not to let your hand pinched, or the robot hand or work part damaged, by the actuator dropping suddenly due to its dead weight. If the actuator cannot be moved by hand, one option is to change parameter No. 28 (Default direction of excited-phase signal detection). If you wish to change this parameter, consult IAI in advance.

 Controller ready (PWR) This signal indicates whether the controller can be controlled externally. When the signal bit is “0,” the controller is busy. When the bit is “1,” the controller is ready. The controller does not become busy in normal conditions of use.

 Servo ON command (SON) The servo will turn on when this signal bit turns “1.” Use this signal if servo on/off must be controlled to provide a safety circuit for the entire system on the PLC side.

 Servo ready (SV) This is a monitor signal indicating, following the input of a servo ON command (SON), that the servo is on and the motor can be driven. The “1”/“0” status of this signal bit is synchronized with the on (green light)/off status of the SV lamp provided on the front panel.

5. Explanation of Operating Functions

1 msec max.

Home return command (HOME)

Home return completion (HEND)

Position complete (PEND)

Moving (MOVE)

Actuator movement

Power on

position

[1] [2]

Mechanical end

Home position

5.3.3 Home Return Operation

This controller uses an incremental position detector (encoder), and will therefore lose its mechanical coordinates once the power is cut off. For this reason, home return must be performed to establish mechanical coordinates every time the power is turned on. To perform home return operation, input a home return command (HOME).

Operation timings PLC processing 1: The home return command (HOME) signal turns ON when the start button is pressed. Operation: [1] The actuator starts moving toward the mechanical end on the home side.

[2] The actuator contacts the mechanical end and reverses its direction, moves to the

home position, and then pauses.

o The home return completion (HEND) signal turns ON. PLC processing 2: The home return command (HOME) signal turns OFF. PLC processing 3: Continuous operation starts.

Caution: Take note of the following points when performing home return:

[1] Confirm that no obstacles are present in the home return path. [2] If any obstacle is found in the home return path, move the actuator to the opposite

direction first and remove the obstacle.

[3] Changing the home return command bit to “1” will change the position complete bit to

“0” and the moving output bit to “1.” Reset the home return command bit to “0” after confirming that the home return completion bit has turned “1.”

5. Explanation of Operating Functions

 Home return command (HOME) Home return operation will start upon detection of the “0” o “1” edge of this signal bit. When home return is completed, the home return completion (HEND) signal will be output. The HOME signal can be input as many time as desired even after home return has been completed once.

(Note) Even if home return is not performed after the power has been turned on, the actuator will automatically

perform home return operation as part of the first positioning operation (CSTR signal).

 Home return completion (HEND) This signal bit is “0” immediately after the power has been turned on. It will turn “1” at the following timings: [1] Home return operation initiated by the HOME signal has completed. [2] Home return operation performed as part of the first positioning operation initiated by the CSTR signal has

completed. Once turning “1,” this signal bit will not turn “0” until the input power is cut off or the HOME signal is input again. Use this signal as an interlock signal to confirm that the actuator is safe to perform home return.

5. Explanation of Operating Functions

5.3.4 Positioning Operation

First, change the position complete (PEND) signal bit to “1” by turning on the 24-VDC power by referring to 5.3.2. Home return is not yet complete immediately after the power has been turned on. Accordingly, home return operation must be performed using the home return command (HOME) as explained in 5.3.3. When positioning operation is started (using the CSTR signal) after specifying a position (via position number specification or direct position data specification), the actuator will perform home return operation and then move to the specified position.

An example of performing positioning operation using an actuator with a 400-mm stroke is explained below.

Example of position table

*T1: Set to T1 t 0 (ms) by considering the scan time of the host controller.

Comment

Position

[mm]

Speed

[mm]

Acceleration

[G]

Deceleration

[G]

Push

[%]

Positioning

band [mm]

Position command

Positioning start (CSTR)

Position complete (PEND)

Completed position

Home return completion (HEND)

Moving (MOVE)

Actuator movement

Speed

Position 1 Position 2

Position

1 Position 2

Positionin

band

Mechanical end

Home position

Time

5. Explanation of Operating Functions

Explanation of operation

[1] When the servo becomes ready after the supply voltage has been turned on, the servo ready (SV) and

position complete (PEND) bits will turn “1.” After confirming that PEND is “1,” specify position 1 and change the positioning start (CSTR) bit to “1.” As for the method of position specification, specify a desired position using six bits from PC1 to PC32, or directly specify it as a numerical value in the register PCMD. o PEND will turn “0,” while the moving (MOVE) bit will turn “1,” as soon as the actuator starts home return

operation.

[2] Change CSTR to “0” after confirming that MOVE has turned “1.”

o The moment the home return is completed (HEND turns “1”), the actuator will start moving to position 1.

[3] When the actuator enters the positioning band (INP) specified with respect to the command value for position

1, PEND will turn “1,” while MOVE will turn “0,” and the completed position number will also be output in the form of six bits from PM1 to PM32 in the register POSS.

[4] Next, specify position 2 and change CSTR to “1,” in the same manner as explained in [1]. The actuator will

start moving to position 2.

[5] Positioning to position 2 will complete in the same manner as explained in [3].

Caution: When the start signal turns ON, the position complete signal will turn OFF and the moving

output will turn ON.

Always turn OFF the start signal after confirming that the moving output has turned ON (position complete output has turned OFF). If the start input remains ON, the position complete output will not turn ON even after the actuator has completed the specified movement, as shown below.

Start

Position

complete

1 msec max.

Movement is complete.

Moving

Actuator

5. Explanation of Operating Functions

 Positioning start (CSTR) Upon detecting the “0” o “1” leading edge of this signal bit, the controller will read the target position number specified by a binary code consisting of six bits from PC1 to PC32 (in the position number specification register) and cause the actuator to move to the target position of the corresponding position data. Before positioning is performed, however, the target position, speed and other operation data must be set in the position table using a PC/teaching pendant. If this command is issued when home return operation has never been performed (= the HEND output signal bit is “0”) after the power was turned on, the actuator will perform home return operation automatically and then move to the target position.

 Moving (MOVE) This signal is output while the actuator is moving (also during home return, push & hold operation and jogging) with the servo turned on. Use this signal together with PEND to determine the actuator status from the PLC side. This signal bit will turn “0” upon completion of positioning, upon completion of home return, after push & hold completion judgment during push & hold operation, and during pause.

 Command position number (PC1 to PC32) When a moving command is executed at the “0” o “1” edge of the CSTR signal bit, a binary code specified by six signal bits from PC1 to PC32 will be read as the command position number.

 Completed position number (PM1 to PM32) These signals can be used to check the completed position number effective when the PEND signal bit has turned “1.” These signals are output as a binary code in the position number status register. Immediately after the power has been turned on, all signal bits from PM1 to PM32 are “0.” All bits remain “0” while the actuator is moving. As evident from the above explanation, these signals are output only upon completion of positioning. Although all signal bits will turn “0” when the servo is turned off or an emergency stop is actuated, the bits will return to “1” when the servo is turned on again, if the actuator is inside the positioning band with respect to the target position. If the actuator is not inside the positioning band, the signal bits will remain “0.” These bits will also turn “1” when the push & hold completion judgment signal has turned ON, or the actuator has missed the work part, during push & hold operation.

5. Explanation of Operating Functions

 Position complete (PEND) This signal indicates that the target position has been reached, and turns ON only when the following conditions are satisfied:

[1] The servo ready (SV) bit is “1” AND [2] the current position has reached the positioning band before each target position OR

[3] the actuator has not missed the work part during push & hold operation. Use this signal as a trigger signal to operate peripheral equipment upon reaching the target position. Increasing the positioning band will allow a command to be issued more quickly to peripheral equipment, which will effectively shorten the tact time of the entire system.

When the servo turns on after the power on, the current position will become the target position. As a result, this signal bit will turn “1.” It will turn “0” if positioning operation is started thereafter with the CSTR signal bit changing to “1.”

(Note) If the servo is turned off or an emergency stop is actuated while the actuator is stopped at the target

position, PEND will change to “0.” When the servo is turned on again, PEND will return to “1” if the actuator is inside the positioning band. If CSTR remains “1,” PEND will not become “1” even if the current position is inside the positioning band. It will turn “1” only after CSTR has turned “0.”

The position complete signal turns ON here.

Target position

Speed

Travel

Time

Positioning band

5. Explanation of Operating Functions

5.3.5 Push & Hold Operation

Just like with an air cylinder, the end of the rod can be pressed against a work part and maintained in this condition. The push & hold operation is useful in clamping or press-fitting of work parts.

(1) Basic operation As shown below, the actuator moves to the specified target position, after which it will move at the specified push speed to push the work part over a distance up to the specified positioning band. If the push force reaches a certain level while the actuator is still pushing the work part, the controller will recognize that push & hold operation has completed and change the position complete signal bit to “1.”

x Definition of push direction

As shown above, the push direction is positive (+) when the actuator pushes the work part in the direction of increasing coordinate value from the starting point toward the target position, whereas the push direction is negative (-) when the actuator pushes the work part in the direction of decreasing coordinate value. Here, exercise caution because setting a wrong push direction will prevent the actuator from operating correctly; specifically, the actuator will perform push & hold operation only for twice the positioning band at the starting point.

Target position

Speed

Travel

Positioning band (Maximum push amount)

The actuator contacts the load and the position complete signal turns ON here because push & hold operation is deemed to have completed.

Push speed

Actuator

Home

Starting point

Home

Starting point

Positioning band

(Sign +)

Push direction

Positioning band

(Sign -)

Speed

X When the negative

sign (-) is set

Target

Position

X When the positive

sign (+) is set

Positioning

band

Positioning

band

Positioning

band

Positioning

band

Starting point

Push direction

Target point

5. Explanation of Operating Functions

[1] Specification of push & hold mode

x Set a value (current-limiting value) “other than 0” in the “Push” field of the position table.

x To specify the push & hold mode numerically, set bit 0 of the control flag specification register CTLF to “1.”

[2] Push speed

Set a desired push speed in parameter No. 34 (Push speed).

(An appropriate push speed has been set at the factory in accordance with the actuator model.) [3] Maximum push amount

x Set a desired amount in the “Positioning band” field of the position table.

x To specify the maximum push amount numerically, set the applicable value in the positioning band

register (INP). (Consider a position error that may generate when installing the work part, and if the work part is made of elastic material, also consider a possible deflection.)

[4] Push direction

x The push direction is specified by the sign in the “Positioning band” field of the position table.

x To specify the push direction numerically, set bit 1 of the control flag specification register CTLF to “0” or

“1.”

[5] Push & hold completion judgment

x Push & hold completion judgment is made based on the generated motor torque (push force) and push

time.

x Set the push force as a current-limiting value (%) in the “Push” field of the position table. To specify the

push force numerically, set the applicable value in the push-current limiting value during push & hold operation register (PPOW).

* Determine an appropriate push force based on the characteristics (shape, material, etc.) of the work part,

and then determine the corresponding current-limiting value using the relation diagram of “push force and current-limiting value” for the applicable actuator.

x Set the push & hold stop judgment period in parameter No. 6.

(The factory setting is 255 msec.)

[6] Continuous push & hold

x Although the position complete signal turns “1” once a completion of push & hold operation is recognized,

the actuator will perform the push & hold operation continuously until the next movement command is issued (command position number and positioning start signals are output).

Warning

x If the actuator contacts the work part before reaching the target position, a servo error alarm will

generate. Pay due attention to the position relationship of the target position and the work part.

x Even when the actuator appears stationary, it actually continues to push the work part at the push force

determined by the current-limiting value. Since the actuator is not physically stopped, exercise due caution when handling any actuator-related operation during this period.

5. Explanation of Operating Functions

Speed

Target position

Positioning band (Maximum push amount)

Push & hold operation was determined complete here.

Travel

(Note) If the actuator is pushed back to the target position, an alarm will generate.

(2) The work part is missed during push & hold operation If the actuator did not contact the work part after moving the specified positioning band (= the motor current does not reach the current-limiting value during push & hold operation), the position complete signal will not be output. However, the applicable completed position number will still be output. At that time, the PSFL bit in the device status register (DSS1) will turn “1.” Therefore, program the host PLC to perform a timeout check based on a sufficient timeout period.

(3) The work part moves after completion of push & hold operation [1] The work part moves in the push direction

If the work part moves in the push direction after completion of push & hold operation, the actuator will chase

the work part within the positioning band.

If the current drops below the current-limiting value set during push & hold operation, the position complete

signal will turn OFF. The signal will turn ON when the current rises to or above the current-limiting value

again.

[2] The work part moves in the opposite direction

(The actuator is pushed back by a strong reactive force of the work part)

If the actuator is pushed back after the push & hold operation has completed because the push force of the

actuator is smaller than the reactive force of the work part, the actuator will be pushed back all the way until

its push force balances out with the reactive force of the work part.

The position complete signal remains ON.

Speed

Travel

Target position

Positioning band (Maximum push amount)

The position complete signal does not turn ON if the actuator did not contact the load.

Speed

Travel

Target position

Positioning band (Maximum push amount)

Push & hold operation was determined complete here.

If the load shifts in the push direction, the actuator chases the load within the positioning band.

5. Explanation of Operating Functions

(4) The push direction is set incorrectly Exercise caution when setting the push direction, because if the direction is set incorrectly, the position will deviate by twice the positioning band, as shown below.

Speed

Target position

Positioning band

Travel

Positioning band Positioning band

ctual operation

Intended operation

Actual position reached

(the load is missed)

5. Explanation of Operating Functions

Speed

Command position

Positioning start

(CSTR)

Position complete

(PEND)

Completed position

Pause command

(STP)

Moving (MOVE)

Actuator movement

4 msec max.

Deceleration to a stop

Start of movement to complete the remaining travel

5.3.6 Pause

When the pause command (STP) bit is changed to “1” while the actuator is moving, the actuator will decelerate to a stop. Since the remaining travel is held, changing STP to “0” again will resume the movement to complete the remaining travel.

Changing the alarm reset (RES) bit to “1” while the actuator is paused will cancel the remaining travel. When a cancellation of the pause command (STP) is recognized thereafter, the position complete signal (PEND) will turn “1” in approx. 1 msec. (The remaining travel will be cancelled upon detection of the leading edge of the reset signal.)

Speed

Command position

Positioning start

(CSTR)

Position complete

(PEND)

Completed position

Pause command

(STP)

Reset (RES)

Moving (MOVE)

Actuator movement

pprox. 1 msec

5. Explanation of Operating Functions

Position command

Positioning start (CSTR) Position complete (PEND)

Completed position

Moving (MOVE)

Actuator movement

Speed

Position 1 Position

Position

Position 2

Position 1 (200 mm)

Position 2 (300 mm)

Comment

Position

[mm]

Speed

[mm]

Acceleration

[G]

Deceleration

[G]

Push

[%]

Positioning

band [mm]

5.3.7 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.

The speed change operation explained above is useful when, among others, the load is made of soft material or is a bottle or other shape that easily topples and you don’t want to give vibration or shock to the work part when the actuator stops.

(Example) Move the actuator to position 2 (300 mm from the home) at 200 mm/sec until interim position 1 (200

mm from the home) and at 20 mm/sec thereafter.

Example of position table

*T1: Set to T1 t 0 (ms) by considering the scan time of the host controller.

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

5. Explanation of Operating Functions

(Note) If a pause command is issued while home return is in progress, the movement command will be held if

the actuator has not yet contacted the mechanical end. If the actuator has already contacted the mechanical end and reversed, home return will be performed again from the beginning.

 Alarm reset (RES) Alarms will be reset at the “0” o “1” leading edge of this signal bit. If any alarm remains whose cause is not yet removed, the same alarm will generate again. If an alarm reset is performed while the actuator is paused, the remaining travel will be cancelled.

Caution: [1] When the start (CSTR) signal is changed to “1,” the position complete (PEND) bit will

turn “1,” while the moving (MOVE) bit will turn “1.” Change the start (CSTR) signal bit to “1” after confirming that the moving (MOVE) signal bit has turned “1.”

[2] Setting a wider positioning band for position 1 will allow for smooth speed change

without causing the actuator to stop.

5. Explanation of Operating Functions

Position command

Acceleration/ deceleration command

Position complete (PEND)

Completed position

Moving (MOVE)

Actuator movement

Speed

Position 1

Acceleration Deceleration

Position 1

Acceleration De

celeration

5.3.8 Operation at Different Acceleration and Deceleration

(1) When the actuator is used in the position number specification mode, acceleration and deceleration can be

set differently in the position table.

(2) Numerical specification mode

Acceleration/deceleration data (set in the register 9906H) becomes effective when the data is received. To set a deceleration different from an acceleration, therefore, change the acceleration/deceleration data while the actuator is moving.

(Example)

5. Explanation of Operating Functions

Zone signal

Actuator operation

Home

Zone setting- Zone setting+

+ direction

5.3.9 Zone Signal

This signal is output (the bit turns “1”) when the current actuator position is inside the specified zone. The zone signal can be used for the following purposes: [1] As an interlock signal to prevent contact with peripheral equipment [2] As a trigger signal for peripheral equipment to shorten the tact time [3] For determining if the actuator has missed the work part during push & hold operation [4] To determine if the actuator has reached the final point of constant pitch feed over aligned work parts

(Note) In constant pitch feed, the “Position” field of the position table indicates an incremental travel.

However, the zone must be set using absolute coordinates with respect to the home.

Setting Zone si

gnal

Position number

specification mode

Numerical

specification mode Individual zone boundaries in the position table

Position zone output PZONE

{

Zone boundary 1 user parameters (Parameter Nos. 1 and 2)

Zone output 1 ZONE1

{ {

Zone boundary 2 user parameters (Parameter Nos. 23 and 24)

Zone output 2 ZONE2

{ {

* The zone signal is output to the zone status register (address 9013H).

When the actuator enters the zone, the bit will turn “1.” The bit remains “0” when the actuator is outside the zone. This signal becomes effective after completion of home return. It will remain effective even when the servo is off, as long as home return has been completed.

5. Explanation of Operating Functions

Position 1

50-mm pitch

To front end

Last load

Zone output signal

The coordinate of the load immediately before the last load is set as the + boundary.

5.3.10 Pitch Feed by Incremental Specification

A target position can be specified in the position table using an incremental travel. This function is useful in operation involving multiple positioning points set apart by an equal distance (constant pitch feed).

(1) Operation example in the position number specification mode The following example explains how to perform positioning at a 50-mm pitch, starting from position No. 1. In this case, create the position table shown below. Whether the operation has completed is determined by the PLC by keeping a count of individual movements. The zone signal can be used to double-check the completion of operation.

Example of position table

Position

[mm]

Zone+

[mm]

Zone-

[mm]

Incremental Comment

On the teaching pendant screen, this symbol indicates that the data is specified in the incremental mode.

5. Explanation of Operating Functions

*T1: Set to T1 t 0 (ms) by considering the scan time of the host controller.

[Explanation of operation]

[1] Perform positioning operation to position 1 (100.00 mm). [2] When the positioning to position 1 has completed, the position complete (PEND) bit turns “1.” The zone

(PZONE) signal bit also turns “1.” Switch the position number from 1 to 2, and change the start (CSTR) bit to “1.”

[3] The moment the actuator starts moving, the position complete (PEND) bit changes from “1” to “0” and

the moving (MOVE) bit changes from “0” to “1.” After confirming that MOVE has turned “1,” change the start (CSTR) bit to “0.”

[4] After the actuator has moved 50 mm, again the position complete (PEND) bit turns “1” and the moving

(MOVE) bit turns “0.” The PLC increments its movement count by 1. Next, change the start (CSTR) bit to “1” for the second 50-mm movement.

[5] Repeat steps [3] and [4] hereafter.

The PLC checks the zone (PZONE) signal status upon completion of positioning. If the signal bit is “0,” the PLC will determine that the position of the last work part has been reached. If the count kept by the PLC does not match the zone signal status, signal timings may not be synchronized.

Command position

Start

(CSTR)

Position complete

(PEND)

Completed position

Moving (MOVE)

Zone signal

(PZONE)

Actuator movement

Speed

Position 1 Position 2

Position 1

Position 2 Po

sition 2

[1]

[2] [3] [4] [5]

Time

Distance from home

5. Explanation of Operating Functions

Command position

Start

Position complete

Completed position

Moving

Actuator movement

Position 1 Position 2

Position 2

Speed

Position Speed

Position from home: 40

Distance

(2) Note on positioning operation If a start signal is input after selecting and inputting a position number by incremental specification while the actuator is performing positioning operation, the actuator will move to the position representing the initial position plus the incremental travel. (If the specified incremental travel is a negative value, the actuator will move to the position representing the initial position minus the specified travel.) Example) Inputting a start signal for position 2 while the actuator is moving to position 1 will cause the actuator to

move to the position 40 mm from the home.

If a start signal is input multiple times for a position number by incremental specification while the actuator is performing positioning operation, the actuator will move to the position representing the initial position plus the “incremental travel x number of times the signal was input.” Example) Inputting a start signal twice for position 2 while the actuator is moving to position 1 will cause the

actuator to move to the position 50 mm from the home.

Command position

Start

Position complete

Completed position

Moving

Actuator movement

Position 1 Position 2

Position 2

Position from home: 50

Distance

Speed

5. Explanation of Operating Functions

Command position

Start

Position complete

Completed position

Actuator movement

Position 1 Position 2

Position 2

Speed

Position Speed

Distance

(3) Note on push & hold operation If a start signal is input after selecting and inputting a position number (for push & hold operation) by incremental specification while the actuator is moving in the push & hold mode, the actuator will move by the incremental travel from where the start signal was input. Therefore, the end position will become indeterminate. Example) Inputting a start signal for position 2 while the actuator is moving to position 1 in the push & hold mode

will cause the actuator to move to the position 10 mm from where the start signal was input.

5. Explanation of Operating Functions

5.3.11 Power-Saving Mode at Standby Positions

One general feature of pulse motors is that their holding current is greater than AC servo motors in a standstill state. Therefore, we provide a power-saving mode to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. Use this function after confirming that it will not present problems to any part of your system. Specifically, the full servo control mode can be selected for saving power in the following three conditions:

(1)

When the actuator stands by with the servo on after the power has been turned on (before home return is completed)

(2)

When the actuator stands by after the home return operation effected by the HOME input signal has completed

(3) When the actuator stands by after reaching the target position

Set “0” or “4” in parameter No. 53.

tting

Disable power-saving mode (complete stop) 0

Full servo control mode 4

 Full servo control mode The pulse motor is servo-controlled to reduce the holding current. Although the exact degree of current reduction varies depending on the actuator model, load condition, etc., the holding current decreases to approx. one-half to one-fourth. Since the servo remains on, no position deviation occurs. The actual holding current can be checked in the current monitor screen of the PC software. Take note that micro-vibration or noise may occur in certain conditions where external force is applied, or depending on the position where the actuator has stopped. If micro-vibration or noise presents problem, do not use this mode.

Caution: In push & hold operation, the full servo control mode becomes ineffective once the

operation has completed successfully. If the actuator has missed the work part, the full servo control mode becomes effective.

5. Explanation of Operating Functions

6. Parameter Settings

6.1 Parameter Table

Parameters are classified into four types according to their content. Category: a: Parameter relating to the actuator stroke range

b: Parameter relating to the actuator operating characteristics c: Parameter relating to the external interface d: Servo gain adjustment

No. Category Symbol Name Unit Default factory setting

1 a ZONM Zone boundary 1+ mm Effective actuator length

2 a ZONL Zone boundary 1– mm Effective actuator length

3 a LIMM Soft limit+ mm Effective actuator length

4 a LIML Soft limit– mm Effective actuator length

5 a ORG

Home return direction (0: Reverse/1: Forward)

(In accordance with the specification at the

time of order)

6 b PSWT Push & hold stop judgment period msec 255

7 d PLG0 Servo gain number -

Set individually in accordance with the

actuator characteristics.

8 b VCMD Default speed mm/sec

Set individually in accordance with the

actuator characteristics.

9 b ACMD Default acceleration/deceleration G

Set individually in accordance with the

actuator characteristics.

10 b INP Default positioning band (in-position) mm 0.10

12 b SPOW Current-limiting value at standstill during positioning %

Set individually in accordance with the

actuator characteristics.

13 b ODPW Current-limiting value during home return %

Set individually in accordance with the

actuator characteristics.

16 c BRSL SIO communication speed bps 230400

17 c RTIM Minimum delay time for slave transmitter activation msec 5

22 a OFST Home return offset mm

Set individually in accordance with the

actuator characteristics.

23 a ZNM2 Zone boundary 2+ mm Effective actuator length

24 a ZNL2 Zone boundary 2– mm Effective actuator length

28 b PHSP1

Default direction of excited-phase signal (0: Reverse/1: Forward)

Set individually in accordance with the

actuator characteristics.

29 b PHSP2 Excited-phase signal detection time msec

Set individually in accordance with the

actuator characteristics.

31 d VLPG Speed loop proportional gain -

Set individually in accordance with the

actuator characteristics.

32 d VLPT Speed loop integral gain -

Set individually in accordance with the

actuator characteristics.

33 d TRQF Torque filter time constant -

Set individually in accordance with the

actuator characteristics.

34 b PSHV Push speed mm/sec

Set individually in accordance with the

actuator characteristics.

35 b SAFV Safety speed mm/sec 100

39 c FPIO

Output mode of position complete signal (0: PEND/1: INP)

- 0 [PEND]

45 c SIVM Silent interval multiplication factor times 0 (Multiplication factor is not applied)

46 b OVRD Speed override % 100

53 b CTLF Default standstill mode - 0 [Complete stop]

(Note) The numbers are displayed in the PC software, but not on the teaching pendant.

Skipped numbers are not used and therefore omitted. The classification codes are provided for the sake of convenience and are not displayed either in the PC software or on the teaching pendant.

6. Parameter Settings

6.2 Detailed Explanation of Parameters

If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power.

6.2.1 Parameters Relating to the Actuator Stroke Range

z Soft limit (No. 3/4 LIMM/LIML) Set the soft limit in the positive direction in parameter No. 3, and that in the negative direction in parameter No. 4. The factory setting for the soft limits conforms to the effective actuator length. Change the settings, as necessary, to prevent crash with an obstacle or when the actuator must be stroked slightly beyond its effective length. A wrong soft limit setting will cause the actuator to crash into the mechanical end, so exercise due caution. The minimum setting unit is “0.01 [mm].” (Note) To change a soft limit, set a value corresponding to 0.3 mm outside of the effective range.

Example) Set the effective range to between 0 mm and 80 mm

Parameter No. 3 (positive side) 80.3 Parameter No. 4 (negative side) –0.3

z Home return direction (No.5 ORG) Unless specified by the user, the home return direction is set to the motor direction at the factory. Should a need arise to change the home direction after the actuator has been assembled into your system, reverse the setting in parameter No. 5 between “0” and “1.” If necessary, also change the parameters for home return offset, soft limits and direction of excited-phase signal detection.

Caution: The home cannot be set on the opposite side for rod-type actuators.

Soft limits set in the controller

pprox.

0.3 mm

Effective range

Allowable jogging/inching range after home return

Approx. 0.1 mm

Approx.

0.3 mm

8 0

6. Parameter Settings

(Home)

z Home return offset (No.22 OFST) The controller is shipped from the factory with an optimal value set in parameter No. 22, so the distance from each mechanical end to the home becomes uniform. The minimum setting unit is “0.01 [mm].” The home return offset can be adjusted in the following conditions: [1] Want to align the actuator home and the system’s mechanical home after the actuator has been assembled

into the system [2] Want to set a new home after reversing the factory-set home direction [3] Want to eliminate a slight deviation generated after replacing the actuator

Caution: If the home return offset has been changed, the soft limit parameters must also be

adjusted accordingly.

z Zone boundary (1: No.1/2 ZONM/ZONL, 2: No.23/24 ZNM2/ZNL2) These parameters set the zone in which the zone output signal (ZONE1 or ZONE2) turns ON. The zone output signal turns ON when the current position is inside the negative (–) boundary and positive (+) boundary settings. For the ZONE1 signal, set the + boundary in parameter No. 1 and – boundary in parameter No. 2. For the ZONE2 signal, set the + boundary in parameter No. 23 and – boundary in parameter No. 24. The minimum setting unit is “0.01 [mm].” Example) Use ZONE1 as an intermediate LS for a range of 100 to 200 mm, and ZONE2 for quick position

check covering a range of 270 to 275 mm, on an actuator having a 300-mm stroke. Parameter No. 1 (+) 200 / Parameter No. 2 (–) 100 Parameter No. 23 (+) 275 / Parameter No. 24 (–) 270

ZONE1 turns ON

ZONE2 turns ON

6. Parameter Settings

6.2.2 Parameters Relating to the Actuator Operating Characteristics

z Default speed (No.8 VCMD) The factory setting is the rated speed of the actuator. When a target position is set in an unregistered position table, the setting in this parameter will be used as the speed data for the applicable position number. To reduce the default speed from the rated speed, change the setting in parameter No. 8.

z Default acceleration/deceleration (No.9 ACMD) The factory setting is the rated acceleration/deceleration of the actuator. When a target position is set in an unregistered position table, the setting in this parameter will be used as the acceleration/deceleration data for the applicable position number. To reduce the default acceleration/deceleration from the rated acceleration/deceleration, change the setting in parameter No. 9.

z Default positioning band (in-position) (No.10 INP) The factory setting is “0.10 [mm].” When a target position is set in an unregistered position table, the setting in this parameter will be used as the positioning band data for the applicable position number. Increasing the default positioning band will allow the position complete signal to be output early. Change the setting in parameter No. 10, as necessary.

z Current-limiting value during home return (No.13 ODPW) The factory setting conforms to the standard specification of the actuator. Increasing this setting will increase the home return torque. This setting need not be changed in normal conditions of use. However, if an increased slide resistance causes the home return to complete before the correct position depending on the affixing method, load condition or other factor when the actuator is used in a vertical application, the value set in parameter No. 13 must be increased. (Do not increase the value beyond 75%.)

z Current-limiting value at standstill during positioning (No.12 SPOW) The factory setting conforms to the standard specification of the actuator. Increasing this setting will increase the holding torque at standstill. This setting need not be changed in normal conditions of use. However, to prevent hunting caused by large external force applied while the actuator is at standstill, the value set in parameter No. 12 must be increased. (Do not increase the value beyond 70%.)

z Speed override (No.46 OVRD) Use this parameter when the actuator needs to be moved at a slower speed to prevent danger when the system is initially started for test operation. When movement commands are issued from the PLC, the specified moving speed can be overridden by the value set in parameter No. 46. Actual moving speed = [Specified speed] x [Value of parameter No. 46] y 100 Example) Specified “speed” 500 (mm/s)

Value of parameter No. 46 20 (%) Under the above settings, the actual moving speed becomes 100 mm/s.

The minimum setting unit is “1 [%],” while the input range is “1 to 100 [%].” The factory setting is “100 [%].”

(Note) This parameter is ignored for movement commands issued from a PC or teaching pendant, or movement commands specified

directly as numerical values. If a PC or teaching pendant is connected, a desired speed ratio can be set and applied to actuator operation from the PC or teaching pendant.

6. Parameter Settings

z Default direction of excited-phase signal detection (No.28 PHSP1) When the servo is turned on for the first time after a power on, excited phase is detected. This parameter defines the direction of this detection. The parameter need not be changed in normal conditions. In certain situations, such as when the actuator was contacting a mechanical end or obstacle when the power was turned on and cannot be moved by hand, change the direction that allows the motor to operate smoothly. To do this, set parameter No. 28 to “0” or “1.” If the detection direction should be the same as the home return direction, specify the same value currently set in parameter No. 5 (Home return direction). To set a direction opposite to the home return direction, specify the value different from the one currently set in parameter No. 5 (Home return direction).

(Example 1) Power was turned on when the slider was contacting the bottom mechanical end in a configuration

where the actuator is installed vertically with the motor at the top.

(Example 2) Power was turned on when the slider was contacting the bottom mechanical end in a configuration

where the actuator is installed vertically with the motor at the bottom.

z Excited-phase signal detection time (No.29 PHSP2) When the servo is turned on for the first time after a power on, excited phase is detected. This parameter defines the time of this detection. The parameter need not be changed in normal conditions, because a detection time appropriate for the standard specification of the actuator has been set at the factory. Should an excitation detection error or abnormal operation occur when the servo is turned on for the first time after a power on, one remedial action that can be taken is to change the detection time set in parameter No. 29. If you wish to change this parameter, contact IAI beforehand.

z Safety speed (No.35 SAFV) This parameter defines the feed speed to be applied during manual operation. The factory setting is “100 [mm/sec].” To change this speed, set an optimal value in parameter No. 35. Take note that the maximum speed is 250 mm/sec and that you should set a speed not exceeding this value.

Top

Bottom

Home position

Home return

direction

Direction of excited-

phase si

nal detection

The slider is contacting the bottom mechanical end.

Set the same value.

Top

Bottom

Home position

Home return

direction

The slider is contacting the bottom mechanical end.

Direction of excited-

hase signal detection

Set different values.

6. Parameter Settings

z Default standstill mode (No.53 CTLF) This parameter defines the power-saving mode to be applied when the actuator stands by for a long time while the machine is operating; the actuator stands by for a long time after completing home return operation; or the actuator stands by for a long time after completing positioning operation in the numerical specification mode. Define whether to enable or disable power-saving in parameter No. 53.

tting

All power-saving modes are disabled. 0

Full servo control mode 4

The factory setting is “0 [Disable].”

Full servo control mode

The pulse motor is servo-controlled to reduce the holding current. Although the exact degree of current reduction varies depending on the actuator model, load condition, etc., the holding current decreases to approx. one-half to one-fourth. Since the servo remains on, no position deviation occurs. The actual holding current can be checked in the current monitor screen of the PC software.

6. Parameter Settings

z Push speed (No.34 PSHV) This parameter defines the push speed to be applied after the actuator reaches the target position in push & hold operation. Before the shipment, this speed has been set to a default value appropriate for the characteristics of the actuator. Set an appropriate speed in parameter No. 34 by considering the material and shape of the work part, and so on. Take note that the maximum speed is limited to 20 [mm/sec] even on high-speed types. Use the actuator at push speeds not exceeding this level.

Caution: It is recommended that you set the push speed to 5 mm/sec or above to minimize the

negative effect of push force variation.

z Push & hold stop judgment period (No.6 PSWT) This parameter is used as a condition for determining that the work part was contacted and thus the push & hold operation has completed. As for the specific method of judgment, the push & hold operation is deemed to have completed if the specified current-limiting value has been retained for the time set in parameter No. 6. Set an optimal time matching the current-limiting value, by considering the material and shape of the work part, and so on. The minimum setting unit is “1 [msec],” while the maximum value is “9999 [msec].” The factory setting is “255 [msec].” (Note) If the work part has shifted and the current has changed during the push & hold judgment, the judgment

follows the timing chart shown below. This example assumes a judgment period of 255 msec.

After reaching the push current, it is maintained for 200 msec. The current drops during the subsequent 20-msec period, and accordingly the count is decremented by 20. Therefore, when the operation is resumed the count will start from 180. Since the count will reach 255 after 75 msec at the push current, the controller will determine that the push & hold operation has completed. In this example, the total judgment period is 295 msec.

Push curren

20 msec

Start position

Target position

Counting starts

Counting continues until 200

Count is decremented to 180

Count is incremented to 255

Judgment of push & hold completion

75 msec

Speed

Work part

Positioning band

Push speed

6. Parameter Settings

IAI America ERC2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

CAUTION

1. Using Multiple 24-V Power Supplies

2. PC Software and Teaching Pendant Models

3. Backup of Latest Data

4. Pamphlet on Modbus Protocols

CE Marking

Table of Contents

Safety Guide

1.1 Introduction

1. Overview

1.2 Key Features and Functions

1.3 Differences from Air Cylinder Control

1.4 Meaning of the Model Number

1.5 Specifications

1.6 Warranty

1.7 Transportation and Handling

1.8 Installation Environment and Noise Elimination

1.9 Cabling

2.1 Name of Each Part

2. Installation

2.2 Installation

3.1 Controller

3. Electrical Specifications

3.2 Input/Output Interfaces

3.3 SIO Converter (Optional)

4.1 Basic Configuration with SIO Converter

4. Wiring

4.2 Configuration Using a Gateway Unit

5. Explanation of Operating Functions

5.1 Description of Position Table

5.2 Data Set in the Numerical Specification Mode

5.3 Explanation of Functions

6.1 Parameter Table

6. Parameter Settings

6.2 Detailed Explanation of Parameters