ERC3
Actuator with Integrated Controller
Instruction Manual
Eighth Edition
Please Read Before Use
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Table of Contents
Safety Guide ···················································································································1
Guideline for Control Method····························································································8
Precautions in Operation ·································································································· 9
International Standards Compliances············································································· 13
Names of the Parts ········································································································· 14
Actuator Coordinate········································································································ 23
Starting Procedures ········································································································ 24
Chapter 1 Specifications Check ··············································································· 31
1.1 Product Check ················································································································ 31
1.1.1 Parts················································································································· 31
1.1.2 Teaching Tool ···································································································32
1.1.3 Instruction manuals related to this product, which are contained
in the DVD.······································································································· 32
1.1.4 How to read the model plate············································································33
1.1.5 How to read the model·····················································································34
1.2 Specifications·················································································································· 36
1.2.1 Actuator············································································································ 36
[1] High Output Setting·················································································36
[2] Maximum speed ······················································································38
[3] MAX. Acceleration, Payload Capacity····················································· 40
[4] Driving System • Position Detector ·························································52
[5] Positioning Precision··············································································· 53
[6] Current Limit Value and Pressing Force ················································· 54
[7] Option······································································································ 58
1.2.2 Built-in Controller ····························································································· 59
[1] Basic Specifications················································································· 59
[2] I/O Specifications····················································································· 60
1.2.3 Control Option··································································································62
[1] PIO Converter (Model: RCB-ƑƑƑ)··························································· 62
[2] Quick Teach (Model: RCM-PST-Ƒ)·························································· 66
Chapter 2 Installation ·······························································································69
2.1 Transportation·················································································································69
[1] Handling of Actuator, PIO Converter and Quick Teach ···························69
[2] Handling of Multi-Axes Type···································································· 70
[3] Handling of Robot Mounted on Mechanical Equipment (System) ··········70
2.2 Installation and Storage Environment············································································· 71
[1] Installation Environment··········································································71
[2] Storage • Preservation Environment ······················································· 72
2.3 How to Install ·················································································································· 73
2.3.1 Posture of Actuator Attachment ······································································· 73
2.3.2 Installation of Slider Type ················································································· 74
[1] Attachment of Actuator Body··································································· 74
[2] Load Attachment ·····················································································77
2.3.3 Installation of Rod Type····················································································79
[1] Installation of Actuator Type Unit····························································· 79
[2] Load Attachment ·····················································································84
2.3.4 Noise Prevention and How to Attach Electrical Devices·································· 86
[1] Noise Elimination Grounding (Frame Ground)········································ 86
[2] Precautions regarding wiring method······················································90
[3] Noise Sources and Elimination ······························································· 90
[4] Cooling Factors and Installation······························································90
Chapter 3 Wiring ······································································································ 93
3.1 Positioner Mode 1 (Standard Type)················································································93
3.1.1 Wiring Diagram (Connection of construction devices)····································· 93
3.1.2 PIO Pattern Select and PIO Signal·································································· 94
[1] PIO Pattern (Control Pattern) Selection·················································· 94
[2] PIO Patterns and Signal Assignment······················································95
[3] List of PIO Signals··················································································· 96
3.1.3 Circuit Diagram ································································································ 97
[1] Power Line and Emergency Stop Circuit················································· 97
[2] PIO Circuit ·······························································································98
3.2 Pulse Train Control Mode ·····························································································101
3.2.1 Wiring Diagram (Connection of construction devices)··································· 101
3.2.2 PIO Pattern Selection and PIO Signal··························································· 102
[1] PIO Pattern (Control Pattern) Selection················································ 102
[2] PIO pattern and Signal Allocation·························································· 102
[3] List of PIO Signals················································································· 103
3.2.3 Circuit Diagram ······························································································ 104
[1] Power Line and Emergency Stop Circuit··············································· 104
[2] Command Pulse Train Circuit································································ 105
[3] PIO Circuit ·····························································································106
3.3 Positioner Mode 2 (Extension Type by PIO Converter)················································108
3.3.1 Wiring Diagram (Connection of construction devices)··································· 108
3.3.2 PIO Pattern Selection and PIO Signal··························································· 109
[1] PIO Pattern (Control Pattern) Selection················································ 109
[2] PIO Patterns and Signal Assignment···················································· 110
[3] List of PIO Signals················································································· 112
3.3.3 Circuit Diagram ······························································································ 114
[1] Power Line and Emergency Stop Circuit··············································· 114
[2] PIO Converter to ERC3········································································· 116
[3] PIO Circuit ····························································································· 117
3.4 MEC Mode 1 (Operation with PLC)··············································································123
3.4.1 Wiring Diagram (Connection of construction devices)··································· 123
3.4.2 PIO Pattern Selection and PIO Signal··························································· 124
[1] Operation pattern ·················································································· 124
[2] Operation Patterns and Signal Assignments········································· 125
[3] List of PIO Signals················································································· 126
3.4.3 Circuit Diagram ······························································································ 127
[1] Power Line and Emergency Stop Circuit··············································· 127
[2] PIO Circuit ·····························································································128
3.5 MEC Mode 2 (Operation Using PIO Converter)··························································· 130
3.5.1 Wiring Diagram (Connection of construction devices)··································· 130
3.5.2 PIO Pattern Selection and PIO Signal··························································· 131
[1] Operation pattern ·················································································· 131
[2] Operation Patterns and Signal Assignments········································· 132
[3] List of PIO Signals················································································· 133
3.5.3 Circuit Diagram ······························································································ 134
[1] Power Line and Emergency Stop Circuit··············································· 134
[2] PIO Converter to ERC3·········································································136
[3] PIO Circuit ·····························································································137
3.6 MEC Mode 3 (Solo Operation with Quick Teach)························································· 139
3.6.1 Wiring Diagram (Connection of construction devices)··································· 139
[1] RCM-PST-0 (24V DC power supply type)·············································139
[2] RCM-PST-1 ··························································································· 140
[3] RCM-PST-2/RCM-PST-EU····································································141
3.7 Wiring Method···············································································································142
3.7.1 Wiring of Actuator··························································································· 142
[1] PIO type power and I/O cable (Model : CB-ERC3P-PWBIOƑƑƑ)········· 142
[2] SIO type power and I/O cable (Model : CB-ERC3S-PWBIOƑƑƑ)········· 143
3.7.2 Wiring between PIO Converter and Quick Teach ··········································144
3.7.3 Wiring between PIO Converter and Host Controller (e.g. PLC) ···················· 145
3.7.4 Wiring of PIO Converter Power Line Connector············································ 149
3.7.5 Pulse Converter: AK-04 (Optional accessory) ··············································· 150
3.7.6 Teaching Port Connector Connection of ERC3 Main Unit ·····························151
3.7.7 Connection of SIO Connector of PIO Converter············································ 152
Chapter 4 Operation·······························································································153
4.1 Basic Operation ············································································································153
4.1.1 Basic Operation Methods··············································································· 153
[1] Positioner Mode 1 (PIO Operation of ERC3) ········································ 153
[2] Pulse Train Control Mode (Pulse Train Operation of ERC3)·················154
[3] Positioner Mode 2 (Extended Operation of ERC3)······························· 155
[4] MEC Mode 1 ························································································· 156
[5] MEC Mode 2 ························································································· 157
[6] MEC Mode 3 ························································································· 157
4.1.2 Parameter Settings ························································································158
4.2 Operation in Positioner Mode ·······················································································159
4.2.1 Set of Position Table ······················································································ 159
4.2.2 Operation in Positioner Mode 1 ····································································· 164
[1] PIO Pattern Selection and Main Functions ···········································164
[2] Overview of major Functions································································· 165
[3] Power Supply and Emergency Stop Release (CP, MP, EMG, PEND) ·· 166
[4] Brake release BK ·················································································· 167
[5] Time Constant for Control Signal Input ················································· 167
[6] Operation Ready and Auxiliary Signals·················································168
[7] Operation with the Position No. Input =
Operations of PIO Patterns 0 and 2······················································172
[8] Direct Position Specification (3-point <Solenoid valve> type) =
PIO Pattern 1························································································· 185
4.2.3 Operation in Positioner Mode 2 (Operation Using PIO Converter)················ 197
[1] PIO Pattern Selection and Main Functions ···········································197
[2] Overview of major Functions································································· 198
[3] Power Supply and Emergency Stop Release
(CP24, MPI, MPO, EMG(-))··································································· 199
[4] Time Constant for Control Signal Input ················································· 199
[5] Operation Ready and Auxiliary Signals·················································200
[6] Operation with the Position No. Input =
Operations of PIO Patterns 0 to 3 ·························································209
[7] Direct Position Specification (Solenoid Valve Mode 1) =
Operation of PIO Pattern 4···································································· 226
[8] Direct Position Specification (Solenoid Valve Mode 2)
= Operations of PIO Pattern 5 in PIO Converter···································238
4.3 Operation in Pulse Train Control Mode (How to Operate Pulse Train Control Type) ··· 245
[1] Guideline for PIO Pattern Selection and Supportive Functions ············ 245
[2] Guideline for Supportive Functions······················································· 245
[3] Power Supply and Emergency Stop Release (CP, MP, EMG) ·············· 246
[4] Brake Release BK·················································································246
[5] Time Constant for Control Signal Input ················································· 247
[6] Operation Ready and Auxiliary Signals·················································247
[7] Pulse Train Input Operation··································································· 251
[8] Settings of Basic Parameters Required for Operation·························· 254
[9] Parameter Settings Required for Advanced Operations······················· 257
4.4 Operation in MEC Mode 1 and 2 (Operation with PLC) ···············································259
[1] Outline for Operation Patterns and Functions·······································259
[2] Table for Operational Conditions (Position Table) and
Positioning Complete Signal ································································· 260
[3] Power Supply and Emergency Stop Release ······································· 264
[4] Brake release BK ·················································································· 266
[5] Time Constant for Control Signal Input ················································· 266
[6] Operation when Operation Pattern is “2-Point Stop (2-Point
Positioning)”··························································································· 267
[7] Operation when Operation Pattern is “3-Point Stop (3-Point
Positioning)”··························································································· 268
4.5 Operation in MEC Mode 3 (Test Run with Quick Teach.) ·············································271
4.5.1 Operation Panel Functions ············································································ 271
4.5.2 Operations······································································································ 272
[1] Switches Used for Mode Selection (Auto Њ Manual) ························· 272
[2] Switch Used for Servo ON/OFF Operation ··········································· 272
[3] Switch Used for Home-Return Operation··············································272
[4] Switches Used for Manual Operation····················································272
[5] Switch Used for Brake Release ···························································· 273
[6] Switches Used to Change Positioning Point Number··························· 273
[7] Switches Used for Position Teaching ···················································· 274
[8] Switches and Rotary Knobs Used in Acceleration/Deceleration and
Speed Settings ······················································································277
[9] Switches Used in Test Run···································································· 277
[10] Switches Used in Alarm Reset······························································ 277
4.5.3 Test Run with Operation Panel ······································································ 278
Chapter 5 Power-saving Function
(Automatic Servo-off and Full Servo Functions) ···································· 287
5.1 Positioner Mode 1 and 2······························································································· 287
5.2 Pulse Train Control Mode ·····························································································290
5.3 MEC Mode 1, 2 and 3··································································································· 291
5.3.1 Automatic Servo-off Function········································································· 291
5.3.2 Full Servo Function ························································································293
Chapter 6 Adjustment of Operation ········································································295
6.1 Absolute Reset and Absolute Battery···········································································295
6.1.1 Absolute Reset·······························································································295
[1] Absolute reset procedure from teaching tool ········································295
[2] Absolute reset using PIO······································································· 296
[3] Absolute Battery····················································································298
6.2 High Output Setting and Gain Scheduling Function····················································· 301
6.2.1 High Output Setting························································································ 301
6.2.2 Gain Scheduling Function··············································································301
6.2.3 Setting in Positioner Mode 1 & 2 and Pulse Train Control Mode··················· 301
6.2.4 Setting in MEC Mode 1 to 3···········································································302
6.3 I/O Parameter ··············································································································· 303
6.3.1 Positioner Mode 1, Positioner Mode 2 and Pulse Train Control Mode·········· 304
[1] I/O Parameter List ·················································································304
[2] Detail Explanation of Parameters··························································308
[3] Servo Adjustment ··················································································335
6.3.2 MEC Mode 1, MEC Mode 2 and MEC Mode 3·············································· 338
[1] I/O Parameter List ·················································································338
[2] Detail Explanation of Parameters··························································340
[3] Servo Adjustment ··················································································348
Chapter 7 Troubleshooting·····················································································351
7.1 Action to Be Taken upon Occurrence of Problem·························································351
7.2 Fault Diagnosis ············································································································· 353
7.2.1 Impossible operation of controller··································································353
7.2.2 Positioning and speed of poor precision (incorrect operation) ······················ 358
7.2.3 Generation of noise and/or vibration······························································360
7.3 Alarm Level ··················································································································· 361
7.4 Alarm List······················································································································362
Chapter 8 Actuator Maintenance Check ································································375
8.1 Inspection Items and Schedule ···················································································· 375
8.2 External Visual Inspection ···························································································· 375
8.3 Cleaning························································································································375
8.4 Internal Inspections for Slider Type ··············································································376
8.5 Internal Cleaning for Slider Type ··················································································376
8.6 Grease Supply ··············································································································377
8.6.1 Grease Supply for Slider Type·······································································377
8.6.2 How to Supply Grease on Slider Type ···························································378
8.6.3 Grease Supply for Rod Type·········································································· 380
8.6.4 How to Supply Grease on Rod Type······························································381
8.7 Motor Replacement Process ························································································383
Chapter 9 External Dimensions··············································································385
9.1 ERC3-SA5C··················································································································385
9.2 ERC3-SA7C··················································································································386
9.3 ERC3-RA4C ·················································································································387
9.4 ERC3-RA6C ·················································································································388
Chapter 10 Appendix································································································389
10.1 Input and Output Response Performance When PIO Converter is Used ···················· 389
10.2 Way to Set Multiple Controllers with 1 Teaching Tool ··················································· 390
10.2.1 Connecting Example······················································································ 391
10.2.2 Detailed Connection Diagram of Communication Lines································ 392
10.2.3 Axis No. Setting······························································································ 392
10.2.4 Handling of e-CON connector (how to connect)············································ 393
10.2.5 SIO Converter ································································································394
10.2.6 Communications Cable·················································································· 396
10.3 Conformity to Safety Category ····················································································· 397
[1] System Configuration············································································397
[2] Wiring and setting of safety circuit ························································398
[3] Examples of safety circuits···································································· 400
[4] TP adapter and accessories·································································· 406
10.4 When Connecting Power Supply with + Grounding ····················································· 408
10.5 Example of Basic Positioning Sequence (PIO Patterns 0 to 3 in PIO Converter)········ 409
10.5.1 I/O Assignment······························································································· 409
10.5.2 Ladder Sequence··························································································· 410
[1] Servo ON (Emergency Stop) Circuit ····················································· 410
[2] Operation and Stop Circuit ····································································410
[3] Pause Circuit ························································································· 411
[4] Reset Circuit·························································································· 412
[5] Home Return Circuit·············································································· 413
[6] Decode Circuit of Positioning Complete Position No.··························· 414
[7] Actuator Start Circuit ·············································································414
[8] Position 1 Operation Circuit··································································· 415
[9] Position 2 Operation Circuit··································································· 416
[10] Position 3 Operation Circuit···································································417
[11] Commanded Position No. Output Ready Circuit··································· 418
[12] Commanded Position No. Output Circuit ··············································419
[13] Start Signal Output Circuit····································································· 419
[14] Other Display Circuits (Zone 1, Position Zone, and Manual Mode)······ 420
10.6 Life ································································································································ 421
10.6.1 Product Life of Slider Type············································································· 421
10.6.2 Product Life of Rod Type ··············································································· 421
Chapter 11 Warranty ································································································423
11.1 Warranty Period············································································································ 423
11.2 Scope of the Warranty··································································································423
11.3 Honoring the Warranty·································································································· 423
11.4 Limited Liability ············································································································· 423
11.5 Conditions of Conformance with Applicable Standards/Regulations, Etc.,
and Applications············································································································424
11.6 Other Items Excluded from Warranty ··········································································· 424
Change History ············································································································· 425
1
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.
Operation
Description
Description
1 Model
Selection
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.
2
No.
Operation
Description
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
3
No.
Operation
Description
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.
4 Installation
and Start
(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
2
(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 100: or below).
4
No.
Operation
Description
Description
4 Installation
and Start
(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.
5
No.
Operation
Description
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.
6
No.
Operation
Description
Description
8 Maintenance
and
Inspection
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.
7
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 Degree of Danger and Damage Symbol
Danger
This indicates an imminently hazardous situation which, if the
product is not handled correctly, will result in death or serious
injury.
Danger
Warning
This indicates a potentially hazardous situation which, if the
product is not handled correctly, could result in death or serious
injury.
Warning
Caution
This indicates a potentially hazardous situation which, if the
product is not handled correctly, may result in minor injury or
property damage.
Caution
Notice
This indicates lower possibility for the injury, but should be kept to
use this product properly.
Notice
8
Guideline for Control Method
ERC3 has numerous operation patterns and options to meet many criteria for different applications.
Check Chapter 4 Operation for more details.
When Quick Teach is used with Con mode only Jog Operation is available.
Codes in brackets are model codes
Controller
No.
Type of
Operation
I/O Type Controller Type
Compulsory
Option
Overview
1 Positioner
Mode 1
(Standard
Type)
PIO Type
(NP/PN)
CON Mode
(CN)
– • Select from 3 types of PIO patterns for
the operation method
• Number of maximum positioning points:
16 points
– • An operation by pulse train input is
available.
• There are 2 types of operation methods
(Positioning/Pressing)
2 Pulse Train
Control
Mode
Pulse Train
Control Type
(PLN/PLP)
(Note 1)
CON Mode
(CN)
Pulse Converter
AK-04
• Applicable for open collector pulse train
output
• There are 2 types of operation methods
(Positioning/Pressing)
3 Positioner
Mode 2
(Expansion
Type)
SIO Type
(SE)
CON Mode
(CN)
PIO Converter • Select from 6 types of PIO patterns for
the operation method
• Number of maximum positioning points:
512 points
• Capable for Simple Absolute Type
application
4 MEC Mode 1 PIO Type
(NP/PN)
MEC Mode
(MC)
Quick
(Note 2)
Teach
• The same control as air cylinder is
available
• Simple operation is available with Quick
Teach (teaching pendant)
• There are 2 types of operation patterns
(2-Point Positioning/3-Point
Positioning)
5 MEC Mode 2 SIO Type
(SE)
MEC Mode
(MC)
PIO Converter
Quick
(Note 2)
Teach
• The same control as air cylinder is
available
• Simple operation is available with Quick
Teach (teaching pendant)
• There are 2 types of operation patterns
(2-Point Positioning/3-Point
Positioning)
• Capable for Simple Absolute Type
application
6 MEC Mode 3 SIO Type
(SE)
MEC Mode
(MC)
Quick Teach • Individual operation is available by
Quick Teach
• There are 2 types of operation patterns
(2-Point Positioning/3-Point
Positioning)
Note 1 The pulse train input is the differential input (Line Driver) type. For PLN, PIO is NPN type
and PLP is PNP type.
Note 2 It is also available to use any teaching tool other than Quick Teach.
Caution : The selection of the controller type is determined by the selection of the model code.
The type of built-in controller differs for each type. Since the hardware is different, it
is not possible to select the type with parameters after the product is delivered out.
9
Precautions in Operation
1. It is set to “high output” when the machine is delivered from the factory.
There is a limit in the duty for the high output setting. Even though the transportable weight and
maximum speed decrease, an operation with the duty 100% becomes available if the high
output setting is set invalid in the parameters.
See 1.2.1 Settings for Valid/Invalid of High Output Setting for more details.
2. Set the operation patterns.
There are some operation (PIO) patterns prepared for each model classified by the built-in
controller.
Set the operation pattern and parameters suitable for the operation method of each model.
See Chapter 4 Operation for more details.
Caution : Please note it is very risky when the control sequence and PIO pattern setting do not
match to each other. It may not only cause the normal operation disabled, but also
may cause an unexpected operation.
3. 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.
4. The allowable load moment for the slider type should be within the allowable
range.
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.
5. The overhung for the slider type should be within the allowable range.
Attaching a load beyond the allowable overhang length may generate vibration or abnormal
noise.
6. Do not attempt to apply a rotary torque the rod type.
Doing so may damage the internal component such as the rod stopper, and may result in an
operation failure.
7. Back and forth operation in short distance may wear out the oil film of the
grease.
If the actuator is moved back and forth continuously over a short distance of 30 mm or less,
grease film may run out. As a guide, move the actuator back and forth repeatedly for around 5
cycles over a distance of 50 mm or more after every 5,000 to 10,000 cycles. Keep using the
actuator with the grease worn out may cause malfunction. If it is extreme, flaking may occur on
the guide.
10
8. Do not attempt to hit the slider or rod against an obstacle with high speed.
It may destroy the coupling.
9. 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.
10. Make sure to follow the usage condition, environment and specification range
of the product.
Operation out of the guarantee could cause a drop in performance or malfunction of the
product.
11. Use the dedicated teaching tool.
Check 1.1.2 Teaching Tool for the PC software and teaching pendant available for this
controller.
12. Do not connect Quick Teach while a tool (teaching) is being connected to the
8-pin mini DIN connector on the ERC3 main unit.
Communication between ERC3 and the tool (teaching or PC) becomes unable.
13. Do not connect Quick Teach while a tool is being connected to TP connector
(8-pin mini DIN) on ERC3 side.
Since the communication with Quick Teach cannot be established, ERC3 cannot receive the
high-output invalid command and runs with the high-output setting condition, resulting in a
generation of the voltage drop error due to the capacity drop of the power supply unit inside
Quick Teach.
14. Backup the data to secure for breakdown.
A non-volatile memory is used as the backup memory for this controller. All the registered
position data and parameters are written into this memory and backed-up at the same time.
Therefore, you will not usually lose the data even if the power is shut down. However, make
sure to save the latest data so a quick recovery action can be taken in case when the controller
is broken and needs to be replaced with another one.
How to Save Data
(1) Save the data to CD-R or hard disk with using the PC software
(2) Hard-copy the information of position tables and parameters on paper
15. Clock Setting in Calendar Function
When power is supplied to the PIO converter for the first time, “Error Code 069 Real Time Clock
Vibration Stop Detected” May get generated. In the case this happens, set the current time with
a teaching tool.
If the battery is fully charged, the clock data is retained for approximately 10 days after the
power is turned OFF. Even though the time setting is conducted before the product is shipped
out, the battery is not fully charged. Therefore, there may be a case that the clock data is lost
even with fewer days than described above passed since the product is shipped out.
16. Pulse Train Control Type cannot be operated with the serial communication.
It is able, however, to monitor the current position or the conditions of the status.
11
17. When using Pulse Train Control type, pay close attention to the pulse
frequency; so the frequency will no exceed the actuator specification.
In the pulse train control, the acceleration/deceleration speed is also controlled by the change
of the command pulse frequency from the host controller. Be careful not to exceed the
maximum acceleration/deceleration speed of the actuator. The use of the actuator with
excessive acceleration/deceleration rate may cause a malfunction.
18. For CON Mode Type, an operation cannot be made unless the servo-on signal
and pause signal are input.
(1) Servo ON Signal SON
Servo-on signal SON is selectable from either “Enable” or “Disable” by the parameter.
This setting can be performed in Parameter No.21 “Servo ON input disable selection”.
[Refer to Chapter 7 Parameters.]
If it is set to “Enable”, the actuator would not operate unless turning this signal ON.
If parameter No.21 is set to “1”, SON is made disable. If it is set to “Disable”, the servo
becomes ON and the actuator operation becomes enabled as soon as the power supply to
the controller is turned ON and the emergency stop signal is cancelled.
The factory setting is “0” (Enable). Have the setting that suits the desired control logic.
(2) Pause Signal *STP
The input signal of the pause signal *STP is always ON considering the safety. Therefore,
in general, the actuator would not operate if this signal is not ON.
It is available to make this signal to “Disable”, if this signal is undesirable.
It is settable by parameter No.15 “Pause input disable”.
[Refer to Chapter 7 Parameters.]
If parameter No.15 is set to “1” (Disable), the actuator can operate even if this signal is not
ON.
This parameter is set to “0” (Enable) at delivery.
12
19. Transference of PIO Signal between Controllers
Please note the following when conducting transference of PIO signal between controllers.
To certainly transfer the signal between controllers with different scan time, it is necessary to
have longer scan time than the one longer than the other controller. To ensure to end the
process safely, it is recommended to have the timer setting more than twice as long as the
longer scan time at least.
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Ɣ Operation Image
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䎃
䎃
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Also, if one tries to read the signal that is being re-written by the other, the signal may be read wrongly.
Make sure to read the signal after the rewriting is complete. (It is recommended to have more than 2 scan
periods to wait.) Make sure not to have the output side to change the output until the other side completes
the reading. Also, a setting is made on the input area not to receive the signal less than a certain time to
prevent a wrong reading of noise. This duration also needs to be considered.
20. PLC Timer Setting
Do not have the PLC timer setting to be done with the minimum setting.
Setting to “1” for 100msec timer turns ON at the timing from 0 to 100msec while 10msec timer
from 0 to 10msec for some PLC.
Therefore, the same process as when the timer is not set is held and may cause a failure such
as the actuator cannot get positioned to the indicated position number in Positioner Mode.
Set “2” as the minimum value for the setting of 10msec timer and when setting to 100msec, use
10msec timer and set to “10”.
This controller
(scan time 1msec)
PLC
(e.g. scan time is 20msec)
Output
Process
Input
Process
As shown in the diagram, the input and output
timings of two devices that have different scan
time do not match, of course, when transferring
a signal.
There is no guarantee that PLC would read the
signal as soon as this controller signal turns on.
In such a case, make the setting to read the
signal after a certain time that is longer than the
longer scan time to ensure the reading process
to succeed on the PLC side.
It is the same in the case this controller side
reads the signal.
In such a case, it is recommended to ensure 2
to 4 times of the scan time for the timer setting
margin.
It is risky to have the setting below the scan
time since the timer is also processed in the
scan process.
In the diagram, PLC can only read the input
once in 20msec even though this controller
output once in 1msec.
Because PLC only conducts output process
once in 20msec, this controller identifies the
same output status for that while.
13
International Standards Compliances
This product complies with the following overseas standard.
RoHS Directive CE Marking
{
To be scheduled
14
Names of the Parts
1. Main Body
In this instruction manual, the right and left sides of the actuator is expressed in the way it is placed
horizontally and is looked from the motor side as shown in the figure below.
(1) Slider Type
Right Side
Left Side
Screw Cover Slider
Motor Unit
Screw for motor unit attachment
Front Cover
Base
External I/F Connector
Teaching Port
Opposite Side
of the Motor
Motor Side
(2) Rod Type
Rod
Motor Unit
Screw for motor unit attachment
Rod End Fitting Range of T-groove
External I/F Connector
Teaching Port
Frame
Grease Supply Gate
(Thin-Head Screw)
Right Side
Left Side
Opposite Side
of the Motor
Motor Side
T-groove
Flange Surface
15
2. Motor Unit
1) Status Indicator LED
Following show the controller operation status:
{ : Illuminating × : OFF ڏ : Flashing
LED Status of PIO Output Signal
CON Mode Type MEC Mode Type
SV
(GN)
ALM
(RD)
Operation status
*ALM Output
(Note 1)
Control Power Supply ON ON
Control Power Supply OFF OFF
× ×
Servo OFF OFF
Motor driving power supply
OFF
OFF
Emergency Stop OFF
×
{
Alarm
(Operation cancellation level
or more)
OFF
{
× Servo ON ON
ڏ × During automatic servo-off ON
{ (OR)
In initializing process at
power being ON
OFF
Note 1 The output signals with * mark are the active low signals that turn ON in normal condition and turn
OFF while in abnormal condition.
2) Teaching Port
It is the connector dedicated for the connection of a teaching tool such as PC software.
3) External I/F Connector
It is I/F connector for controls with PIO and SIO.
1) Status Indicator LED (SV/ALM)
2) Teaching Port
3) External I/F Connector
16
3. Option
(1) PIO Converter (Model: RCB-CV/CVG-**)
The functions of CON mode type in ERC3 can be extended. See 4.2.3 Operation in Positioner
Mode 2 for details.
Also, if ERC3 is Simple Absolute Type, the absolute battery is to be attached to this PIO
Converter, thus it is mandatory.
6) Status Indicator LED
5) Absolute Battery LED
(For Simple Absolute Type)
4) Brake Release Switch
3) SIO Connector
1) PIO Connector
11) FG Terminal Block
7) Absolute Reset LED
(For Simple Absolute Type)
8) Mode Changeover Switch
for Status LEDs
(with monitor LED)
9) Status Display Mode LED
(with monitor LED)
10) Status LED
(with monitor LED)
䎽䎃
2) Absolute Battery
(For Simple Absolute Type)
12) Power Supply
Connector
14) Absolute Battery Connector
(For Simple Absolute Type)
Z View
2) Absolute Battery
(For Simple Absolute Type)
13) ERC3
Connector
17
1) PIO Connector (I/O) [Refer to 3.2.2 [2]]
The PIO connector is used for control I/O signals.
2) Absolute Battery [Refer to Chapter 6]
This is the battery to retain the encoder information for Simple Absolute Type. Affix it with
fabric hook-and-loop fastener on the side of PIO Converter.
If ERC3 is Simple Absolute Type, it is necessary that PIO Converter is a type that is
applicable for Simple Absolute Type.
3) SIO Connector (SIO) [Refer to 3.7.6]
This is the connector for the communication cable connection with a teaching tool such as
the PC software.
4) Brake Release Switch (RLS/NOM)
For the actuator equipped with a brake, the switch is used to release the brake forcibly.
RLS ···········Brake release
NOM··········Normal Operation (brake is activated)
Warning : Always set the switch to “NOM” in normal operation.
(Keep the chance to set the switch to RLS side as less as possible, and make
sure to set it on NOM side in ordinary use.)
The brake would not work even with the servo OFF condition if the switch is
on the RLS side. In the vertical oriented mount, the work may drop and cause
an injury or the work to be damaged.
5) Absolute Battery LED (BAT)
It shows the absolute reset status, complete or incomplete.
It is equipped if applicable for Simple Absolute Type.
LED Operation Status
OFF Control Power Supply OFF
Green Light is turned ON. Battery Fully Charged
Orange Light is turned ON. Battery Charging Operation
Red Light is turned ON. Battery Disconnected
18
6) Status Indicator LED (SYS)
Following show the controller operation status:
{ : Illuminating × : OFF ڏ : Flashing
LED Status of PIO Output Signal
CON Mode Type
MEC Mode
Type
SV
(GN)
ALM
(RD)
Operation status
SV Output
(Servo ON)
*ALM Output
(Note 1)
(Alarm)
*EMGS Output
(Note 1)(Note2)
(Emergency
Stop Status)
*ALM Output
(Note 1)
Control Power Supply ON OFF ON ON ON
Control Power Supply OFF OFF OFF OFF OFF
× ×
Servo OFF OFF OFF – OFF
Motor driving power supply
OFF
OFF OFF – OFF
Emergency Stop OFF OFF OFF OFF
×
{
Alarm
(Operation cancellation level
or more)
OFF OFF – OFF
{
× Servo ON ON ON ON ON
ڏ
×
During automatic servo-off
(Note 3)
OFF ON – ON
{ (OR)
In initializing process at power
being ON
OFF OFF – OFF
Note 1 The output signals with * mark are the active low signals that turn ON in normal condition and turn
OFF while in abnormal condition.
Note 2 *EMGS output is not prepared for Pulse Train Control Type.
Note 3 Servo-motor Auto OFF [Refer to Chapter 5 Power-saving Function]
7) Absolute Reset LED (ABS)
It shows the absolute reset status, complete or incomplete.
It is to be mounted to Simple Absolute Type.
LED Operation Status
OFF Control Power Supply OFF
Green Light is turned ON. Absolute Reset Complete
Red Light is turned ON. Absolute Reset Incomplete
8) Mode Changeover Switch for Status LEDs (SCT)
The display modes (0 to 3) of LED 0 to 15 switch over every time the switch is pressed and
the contents of display can be changed. The selection of the mode can be checked with the
color of Status Display Mode LED.
9) Status Display Mode LED (SYS)
The mode selected with Status LED Mode Changeover Switch is expressed with the display
colors.
LED Mode Contents of LED 0 to 15 Displays
OFF Mode 0
Command Current Ratio Level/
Control Power Supply OFF
Green Light is turned ON. Mode 1 Alarm Code
Yellow Light is turned ON. Mode 2 Monitoring of PIO input signal
Red Light is turned ON. Mode 3 Monitoring of PIO output signal
19
10) Status LED (0 to 15)
• Display while Mode 0 (Command Current Ratio Level) being selected
The command current ratio level of the motor rated current as 100% is displayed in a bar
graph with green lights.
{: LED Illuminating, × : LED OFF
Status of LEDs
15 × × × × × × × × × × × × × × × ×
{
14 × × × × × × × × × × × × × × ×
{ {
13 × × × × × × × × × × × × × ×
{ { {
12 × × × × × × × × × × × × ×
{ { { {
11 × × × × × × × × × × × ×
{ { { { {
10 × × × × × × × × × × ×
{ { { { { {
9 × × × × × × × × × ×
{ { { { { { {
8 × × × × × × × × ×
{ { { { { { { {
7 × × × × × × × ×
{ { { { { { { { {
6 × × × × × × ×
{ { { { { { { { { {
5 × × × × × ×
{ { { { { { { { { { {
4 × × × × ×
{ { { { { { { { { { { {
3 × × × ×
{ { { { { { { { { { { { {
2 × × ×
{ { { { { { { { { { { { { {
1 × ×
{ { { { { { { { { { { { { { {
0 ×
{ { { { { { { { { { { { { { { {
Command
Current
Ratio [%]
0
to 6.24
to 12.24
to 18.74
to 24.99
to 31.24
to 37.49
to 43.74
to 49.99
to 56.24
to 62.49
to 68.74
to 74.99
to 81.24
to 87.49
to 93.74
to 100.00
• Display while Mode 1 (Alarm Code) being selected [refer to Chapter 7 for Alarm Codes]
The alarm code issued in ERC3 is displayed in the hexadecimal system with the LED 0 to
15 used as 1 word of bit 0 to 15.
(Example) If Alarm Code “083” (absolute position movement command at home-return
incomplete) is generated, the display is as shown below:
{: LED Illuminating, × : LED OFF
LED 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Alarm Display × × × × × × × ×
{
× × × × ×
{ {
Alarm Code 0 0 8 3
20
• Display while Mode 2 (PIO Input Signal Monitor) being selected
It displays the status of PIO control input (PLC ĺ PIO Converter) whether it is ON or OFF.
[Refer to 2.1 [2]]
LED turned ON in green : input signal ON
LED being OFF : input signal OFF
• Display while Mode 2 (PIO Output Signal Monitor) being selected
It displays the status of PIO control input (PIO Converter ĺ PLC) whether it is ON or OFF.
[Refer to 2.1 [2]]
LED turned ON in green : output signal ON
LED being OFF : output signal OFF
11) FG Terminal Block [Refer to 2.3.4 [1] (2)]
This is the grounding terminal for protection from electric shock and noise. Make sure to
conduct the Class D grounding (formerly Class 3 grounding: grounding resistance at 100 or
less).
12) Power Supply Connector [Refer to 3.3.3 [1], 3.5.3 [1]]
This is the connector for the connections of power supply, emergency stop input, driving
cutoff and the emergency stop switch signal output for the teaching pendant.
13) ERC3 Connector [Refer to 3.3.3 [2], 3.5.3 [2]]
This is the connector for the relay cable to connect ERC3 and PIO Converter.
14) Absolute Battery Connector [Refer to Chapter 6]
It is the connector to plug in the enclosed battery if applicable for Simple Absolute Type.
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