IAI America PCON-CF User Manual
PCON-C/CG/CF
Controller
Positioner Type
Operation Manual Seventeenth Edition
Please Read Before Use
Thank you for purchasing our product.
This Operation Manual explains the handling methods, structure and maintenance of this product, among others,
providing the information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained herein to
ensure safe use of the product.
The CD 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]
x This Operation Manual is original.
x 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.
x Information contained in this Operation Manual is subject to change without notice for the purpose of
product improvement.
x If you have any question or comment regarding the content of this manual, please contact the IAI
sales office near you.
x Using or copying all or part of this Operation Manual without permission is prohibited.
x The company names, names of products and trademarks of each company shown in the sentences
are registered trademarks.
CAUTION
x Changes to Zone Function
Applicable application versions: V0016 and later
Among the zone signal settings, those that result in “Zone setting+ < Zone setting-” are now effective.
V0015 and earlier: “Zone setting+ d Zone setting-” o A zone signal is not output.
V0016 and later: “Zone setting+ = Zone setting-” o This is the only condition in which a zone signal is not output.
Accordingly, you can now output a zone signal even when a rotary actuator is operated over the 0q position in
the index mode.
An example is given below.
[Rotary actuator in index mode]
Zone signal ON range
Set value Set value
Zone setting+: 70q Zone setting+: 315q
Zone setting-: 315q Zone setting-: 70q
[Linear axis]
Current position
Zone signal output
Zone signal output
Set value
Zone setting+: 70 mm
Zone setting-: 30 mm
Set value
Zone setting+: 30 mm
Zone setting-: 70 mm
CAUTION
1. Use Environment
PCON controllers can be used in an environment of pollution degree 2 or equivalent.
2. PC Software and Teaching Pendant Models
New functions have been added to the entire PCON controller series.
To support these new features, the communication protocol has been changed to the general Modbus
(Modbus-compliant) mode. As a result, the existing PC software programs and teaching pendants
compatible with RCP2 controllers can no longer be used.
If you are using this controller, use a compatible PC software program and/or teaching pendant selected
from the following models.
skrameRrebmunledoM
PC software RCM-101-***
Teaching pendant CON-T, RCM-T
Simple teaching pendant RCM-E
Data setting unit RCM-P
Touch panel display RCM-PM-01 Not compatible with RCP2 controllers
All are compatible with existing RCP2
controllers
3. Recommendation for Backing up Latest Data
This product uses nonvolatile memory to store the position table and parameters. Normally the memory will
retain the stored data even after the power is disconnected. However, the data may be lost if the nonvolatile
memory becomes faulty.
We strongly recommend that the latest position table and parameter data be backed up so that the data
can be restored quickly when the controller must be replaced for a given reason.
The data can be backed up using the following methods:
[1] Save to a CD or FD from the PC software.
[2] Create a position table sheet or parameter sheet and keep a written record of backup.
CAUTION
4. Initial Parameter Settings at Startup
After applying power, at least the three parameters specified below must be set in accordance with the
specific application.
Inappropriate settings of these parameters will prevent the controller from operating properly, so exercise
due caution.
For details on how to set the parameters, refer to “Parameter Settings” in the operation manual for the PC
or teaching pendant.
[1] Selecting the PIO pattern
This controller provides six PIO pattern types to meet the needs of various applications.
To select a desired type, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern
selection).
The factory setting is “0 [Standard type].”
Parameter No.
25 setting
0 Standard type
A basic type supporting 64 positioning points and two zone outputs.
* How to set zone boundaries within which to output a zone signal:
Zone boundaries are set using parameter Nos. 1 and 2 for one zone output, and in
the position table for another zone output.
1 Teaching type
In this type, 64 positioning points and one zone output (boundaries are set in the
position table) are supported.
In addition to the normal positioning mode, the user can also select the teaching
mode in which the actuator can be jogged via commands from a PLC and the
current actuator position can be written to a specified position.
(Note 1) Jog commands from a PLC are also accepted in the positioning mode.
(Note 2) Positions can be rewritten by approximately 100,000 times.
2 256-point positioning type
The number of positioning points is increased to 256, so only one zone output is
available (boundaries are set in the position table).
3 512-point positioning type
The number of positioning points is increased to 512, so no zone output is available.
4 7-point type
The number of positioning points is limited to seven to offer separate direct
command inputs and position complete outputs for respective positions.
PLC ladder sequence circuits can be designed easily.
Feature of PIO pattern
5 3-point type
Use of the controller as an air cylinder is assumed in this type.
Position complete output signals function differently in this type, compared to the 7point type.
Specifically, the signal functions not only to “indicate position complete,” but also to
“detect a position” in the same manner as auto-switches of an air cylinder.
CAUTION
[2] Enabling/disabling the servo ON input signal (SON)
The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side.
Depending on the needs, therefore, the user must enable/disable this signal.
To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection).
Enable (use) 0
Disable (do not use) 1
The factory setting is “0 [Enable].”
[3] Enabling/disabling the pause signal (*STP)
The pause signal uses the contact b logic to provide a failsafe function.
Therefore, this signal must remain ON in normal conditions of use.
Since there are applications where this signal is not used, a parameter is provided to disable the pause
signal so it doesn’ t have to be turned ON.
To select a desired setting, set “0” or “1” in parameter No. 15 (Pause input disable selection).
Enable (use) 0
Disable (do not use) 1
The factory setting is “0 [Enable].”
5. Using a Rotary Actuator in Multi-rotation Specification
Rotary actuators of multi-rotation specification models let you select multi-rotation operation or limited-rotation
operation using a parameter.
5.1 Notes
Pay attention to the setting of the PIO pattern parameter for the controllers specified below.
Each controller does not support relative coordination specification in the PIO pattern specified.
[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25)
[2] PCON-CY: PIO pattern = 0 (User parameter No. 25)
5.2 Applicable Models
Actuators
RCP2-RTCL-I-28P-30-360-*
Controllers
*-IP82-C-NOCP*-063-02-P82-I-LBTR-2PCR
*-IP82-GC-NOCP*-063-03-P82-I-LBTR-2PCR
*-IP82-YC-NOCP*-063-02-P82-I-LCTR-2PCR
PCON-SE-28PI-*
CE Marking
If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual
(ME0287) that is provided separately.
Table of Contents
Safety Guide .................................................................................................................... 1
1. Overview ................................................................................................................... 9
1.1 Introduction..........................................................................................................................9
1.2 How to Read the Model Specification................................................................................10
1.3 System Configuration ........................................................................................................ 11
1.3.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)................................................ 11
1.3.2 External Drive-Power Cutoff Relay Type (PCON-CG).................................................. 12
1.4 Procedure from Unpacking to Test Operation and Adjustment ..........................................13
1.5 Warranty............................................................................................................................ 15
1.5.1 Warranty Period.............................................................................................................15
1.5.2 Scope of Warranty.........................................................................................................15
1.5.3 Honoring the Warranty...................................................................................................15
1.5.4 Limited Liability..............................................................................................................15
1.5.5 Conditions of Conformance with Applicable Standards/Regulations, Etc.,
and Applications ........................................................................................................... 16
1.5.6 Other Items Excluded from Warranty............................................................................ 16
2. Specifications .......................................................................................................... 17
2.1 Basic Specifications...........................................................................................................17
2.2 Name and Function of Each Part of the Controller ............................................................18
2.3 External Dimensions..........................................................................................................20
3. Installation and Noise Elimination............................................................................ 21
3.1 Installation Environment ....................................................................................................21
3.2 Power Supply ....................................................................................................................21
3.3 Noise Elimination and Grounding ......................................................................................22
3.4 Heat Radiation and Installation..........................................................................................23
4. Wiring ...................................................................................................................... 24
4.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF) .....................................................24
4.1.1 External Connection Diagram....................................................................................... 24
4.1.2 Wiring the Power Supply/Emergency-Stop Switch....................................................... 25
4.2 External Drive-Power Cutoff Relay Type (PCON-CG) .......................................................32
4.2.1 External Connection Diagram....................................................................................... 32
4.2.2 Wiring the Power Supply/Emergency-Stop Switch....................................................... 33
4.3 Connecting the I/O Cables ................................................................................................36
z PIO pattern 0 [Standard Type].............................................................................................. 36
z PIO pattern 1 [Teaching Type] ............................................................................................. 37
z PIO pattern 2 [256-piont mode] ............................................................................................ 38
z PIO pattern 3 [512-piont mode] ............................................................................................ 39
z PIO pattern 4 [Solenoid valve mode 1]................................................................................. 40
z PIO pattern 5 [Solenoid valve mode 2]................................................................................. 41
4.4 Connecting the Actuator ....................................................................................................43
4.4.1 Connecting the PCON-C/CG and Actuator................................................................... 43
4.4.2 Connecting the PCON-CF and Actuator....................................................................... 45
4.5 Connecting the Communication Cable ..............................................................................46
5. I/O Signal Control and Signal Functions.................................................................. 47
5.1 Interface Circuit
5.1.1 External Input Specifications......................................................................................... 47
5.1.2 External Output Specifications...................................................................................... 48
5.2 PIO Patterns and Signal Assignments
5.2.1 Explanation of Signal Names........................................................................................ 50
z PIO pattern = 0: Positioning mode [Standard type]..............................................................50
PIO pattern = 1: Teaching mode [Teaching type] ................................................................ 51
z
z PIO pattern = 2: 256-point mode [256-point type]................................................................ 52
z PIO pattern = 3: 512-point mode [512-point type]................................................................ 53
z PIO pattern = 4: Solenoid valve mode 1 [7- point type]........................................................54
z PIO pattern = 5: Solenoid valve mode 2 [3-point type].........................................................55
5.2.2 Signal Assignment Table for Respective PIO Patterns................................................. 56
.................................................................................................................47
...............................................................................49
5.3 Details of I/O Signal Functions ..........................................................................................57
5.3.1. Details of Each Input Signal.......................................................................................... 57
Operating mode (RMOD) ..................................................................................................... 57
Start (CSTR) ......................................................................................................................... 57
Command position number (PC1 to PC256)........................................................................ 57
Pause (*STP)........................................................................................................................ 58
Home return (HOME) ...........................................................................................................58
Servo ON (SON)................................................................................................................... 58
Alarm reset (RES) ................................................................................................................ 58
Brake release (BKRL)........................................................................................................... 59
Operation mode (MODE)...................................................................................................... 59
Current-position write (PWRT) ............................................................................................. 59
Manual operation switching (JISL) ....................................................................................... 59
Jog (JOG+, JOG-) ................................................................................................................60
Direct position command (ST0 to ST6) [7-point type] .......................................................... 60
Movement to each position (ST0 to ST2) [3-point type]....................................................... 61
5.3.2 Details of Each Output Signal....................................................................................... 62
Operating mode status (RMDS) ...........................................................................................62
Completed position number (PM1 to PM256) ...................................................................... 62
Moving (MOVE) ....................................................................................................................62
Position complete (PEND).................................................................................................... 62
Home return completion (HEND) ......................................................................................... 63
Zone (ZONE1, ZONE2) ........................................................................................................ 63
Current operation mode (MODES)....................................................................................... 63
Write completion (WEND) ....................................................................................................63
Movement complete at each position (PE0 to PE6) [7-point type]....................................... 64
Position detection output at each position (LS0 to LS2) [3-point type] ................................ 64
Ready (SV) ........................................................................................................................... 64
Alarm (*ALM) ........................................................................................................................ 64
Emergency stop (*EMGS) .................................................................................................... 65
Load output judgment status (LOAD)................................................................................... 65
Torque level status (TRQS).................................................................................................. 65
Output Signal Changes in Each Mode ................................................................................. 65
6. Data Entry <Basics>................................................................................................ 66
6.1 Description of Position Table .............................................................................................66
6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value ...........................70
6.2 Explanation of Modes ........................................................................................................70
6.2.1 Positioning Mode Push = 0........................................................................................... 70
6.2.2 Push & Hold Mode Push = Other than 0 ...................................................................... 70
6.2.3 Torque Check Function in Push & Hold Operation .......................................................73
6.2.4 Speed Change during Movement ................................................................................. 75
6.2.5 Operation at Different Acceleration and Deceleration Settings .................................... 75
6.2.6 Pause............................................................................................................................ 76
6.2.7 Zone Signal Output ....................................................................................................... 76
6.2.8 Home Return.................................................................................................................77
6.2.9
6.2.10 Overview of 7-point Type .............................................................................................. 79
6.2.11 Overview of 3-point Type .............................................................................................. 81
Overview of Teaching Type........................................................................................... 78
6.3 Notes on the ROBO Gripper..............................................................................................83
6.4 Power-saving Modes at Standby Positions........................................................................85
6.5 Using a Rotary Actuator in Multi-rotation Specification ......................................................88
6.5.1 How to Use ...................................................................................................................88
7. Operation <Practical Steps> .................................................................................... 89
7.1 How to S
7.1.1 Timings after Power On ................................................................................................ 89
Procedure after initial startup until actuator adjustment .................................................... 89
Procedure of Normal Operation......................................................................................... 91
7.1.2 Position Table and Parameter Settings Required for Operation................................... 93
Startup adjustment............................................................................................................. 93
Full-scale operation............................................................................................................ 94
tart.......................................................................................................................89
Safety speed during manual feed ...................................................................................... 93
Speed override for movement commands from the PLC .................................................. 93
Saving energy when the actuator stands by for a long time
after the power has been turned on................................................................................... 94
Saving energy when the actuator stands by after completing
the home return operation effected by the HOME input signal.......................................... 94
Saving energy when the actuator stands by for a long time at the target position............ 94
Output mode of complete signal ........................................................................................ 94
7.2 Home Return Operation ....................................................................................................95
7.2.1 Method Using the HOME Input Signal (PIO Pattern = 0 to 4) ...................................... 95
7.2.2 Method Used When No HOME Input Signal Is Available (PIO Pattern = 5)................. 97
7.3 Positioning Mode (Back and Forth Movement between Two Points) .................................98
7.4 Push & Hold Mode...........................................................................................................
7.4.1 Return Action after Push & Hold by Relative Coordinate Specification......................
100
102
7.5 Speed Change during Movement ....................................................................................103
7.6 Operation at Different Acceleration and Deceleration Settings ........................................105
7.7 Pause ..............................................................................................................................107
7.8 Zone Signal Output..........................................................................................................109
7.9 Incremental Moves .......................................................................................................... 112
7.9.1 Judgment Method of End Position.............................................................................. 114
7.9.2 Notes on Incremental Mode........................................................................................ 115
7.10 Jogging/Teaching Using PIO ...........................................................................................118
7.11 Operation in 7-point Type ................................................................................................ 120
7.12 Operation in 3-point Type ................................................................................................124
8. Parameter Settings................................................................................................ 128
8.1 Parameter Table ..............................................................................................................128
8.2 Detail Explanation of Parameters ....................................................................................130
8.2.1 Parameters Relating to the Actuator Stroke Range.................................................... 130
z Soft limit (No.3/4 LIMM/LIML) ..................................................................................... 130
z Software limit margin (No. 88 SWLM) ........................................................................ 130
z Zone boundary (1: No.1/2 ZONM/ZONL 2: No.23/24 ZNM2/ZNL2)........................... 131
z Home return direction (No.5 ORG)............................................................................. 132
z Home return offset (No.22 OFST) .............................................................................. 132
8.2.2 Parameters Relating to the Actuator Operating Characteristics................................. 132
z PIO jog speed (No.26 IOJV) ....................................................................................... 132
z Software limit margin (No. 88 SWLM) ........................................................................ 130
z Zone boundary (1: No.1/2 ZONM/ZONL 2: No.23/24 ZNM2/ZNL2)........................... 131
z Home return direction (No.5 ORG)............................................................................. 132
Home return offset (No.22 OFST) .............................................................................. 132
z
8.2.2 Parameters Relating to the Actuator Operating Characteristics................................. 132
z PIO jog speed (No.26 IOJV) ....................................................................................... 132
PIO inching distance (No.48 IOID) ............................................................................. 132
z
z Default speed (No.8 VCMD) ....................................................................................... 132
z Default acceleration/deceleration (No.9 ACMD)......................................................... 133
z Default positioning band (in-position) (No.10 INP) ..................................................... 133
z Current-limiting value at standstill during positioning (No.12 SPOW) ........................ 133
z Current-limiting value during home return (No.13 ODPW)......................................... 133
z Home sensor input polarity (No. 18, LS)..................................................................... 133
z Speed override (No.46 OVRD) ................................................................................... 133
z Default direction of excited-phase signal detection (No.28 PHSP) ............................ 134
z Excited-phase signal detection time (No.29 PHSP) ................................................... 134
z Safety speed (No.35 SAFV) ....................................................................................... 134
z Automatic servo-off delay time (No.36 ASO1/No.37 ASO2/No.38 ASO3)................. 135
z Default standstill mode (No.53 HSTP)........................................................................ 135
z Push speed (No.34 PSHV) ......................................................................................... 136
z Push completion judgment time (No.6 PSWT)........................................................... 136
z Enable function (No.42 FDIO4) ..................................................................................137
z Polarity of home check sensor input (No.43 AIOF) ....................................................137
z Load output judgment time (No.50 LDWT)................................................................. 137
z Torque check range (No.51 TRQZ)............................................................................ 138
z Ball screw lead length (No.77 LEAD) ......................................................................... 138
z Axis operation type (No.78 ATYP).............................................................................. 138
z Rotational axis mode selection (No.79 ATYP) ...........................................................138
z Shortcut selection for rotational axis (No.80 ATYP) ...................................................138
z Absolute unit (No.83 ETYP)........................................................................................ 139
z Current-limiting value at standstill after missing work part in push & hold operation
(No. 91 PSFC)................................................................................................................. 139
8.2.3 Parameters Relating to the External Interface............................................................ 140
z PIO pattern selection (No.25 IOPN) ........................................................................... 140
z Movement command type (No.27 FPIO).................................................................... 141
z Pause input disable selection (No.15 FPIO)............................................................... 142
z Servo ON input disable selection (No.21 FPIO) ......................................................... 142
z Home-return input disable selection (No.40 FPIO)..................................................... 142
z Operating-mode input disable selection (No.41 FPIO)............................................... 142
z Output mode of position complete signal (No.39 FPIO)............................................. 143
z SIO communication speed (No.16 BRSL) ..................................................................143
z Minimum delay time for slave transmitter activation (No.17 RTIM)............................ 143
z Silent interval multiplier (No.45 SIVM)........................................................................ 144
8.2.4 Servo Gain Adjustment............................................................................................... 145
z Servo gain number (No.7 PLG0) ................................................................................ 145
z Speed loop proportional gain (No.31 VLPG) .............................................................. 145
z Speed loop integral gain (No.32 VLPT)...................................................................... 146
z Torque filter time constant (No.33 TRQF) .................................................................. 146
9. PC/Teaching Pendant Connection Method in Multi-axis Configurations ................ 147
9.1 Connection Example .......................................................................................................147
9.2 SIO Converter (Optional).................................................................................................148
9.3 Address Switch................................................................................................................150
9.4 Connection Cables ..........................................................................................................150
9.5 Detail Connection Diagram..............................................................................................151
10. Troubleshooting..................................................................................................... 152
10.1 Action to Be Taken upon Occurrence of Problem ............................................................152
10.2 Alarm Level Classification ...............................................................................................153
10.3 Alarm Description Output Using PIO ...............................................................................154
10.4 Alarm Description and Cause/Action ...............................................................................155
(1) Message level alarms......................................................................................................... 155
(2) Cold-start level alarms........................................................................................................ 160
10.5 Messages Displayed during Operation Using the Teaching Pendant ..............................162
10.6 Specific Problems............................................................................................................165
z I/O signals cannot be exchanged with the PLC.................................................................. 165
z
The ALM lamp illuminates when the power is input. .......................................................... 165
z The SV lamp does not illuminate when the servo ON signal is
input after the power was input.
z Home return ends in the middle in a vertical application....................................................166
z Noise occurs during downward movements in a vertical application................................. 166
z Vibration occurs when the actuator is stopped................................................................... 166
z The actuator overshoots when decelerated to a stop. ....................................................... 166
z The home and target positions sometimes shift................................................................. 166
z The speed is slow during push & hold operation................................................................ 166
z The actuator moves only a half of, or twice as much as, the specified movement............ 166
z A servo error occurred while the actuator was moving (ROBO Gripper)........................... 167
z Abnormal operation results when the servo is turned ON after the power ON.................. 168
z The SV lamp blinks............................................................................................................. 168
......................................................................................... 165
* Appendix.................................................................................................................... 169
List of Specifications of Connectable Actuators.........................................................................169
Correlation diagram of speed and loading capacity for the slider type (motor-straight type).....181
Correlation diagram of speed and loading capacity for the slider type (motor-reversing type)..182
Correlation diagram of speed and loading capacity for the standard rod type...........................183
Correlation diagram of speed and loading capacity for the single-guide type ...........................184
Correlation diagram of speed and loading capacity for the double-guide type..........................185
Correlation diagram of speed and loading capacity for the dustproof/splash-proof type ...........186
Correlation diagram of speed and load capacity for the high-thrust type ..................................187
Correlation diagram of speed and loading capacity for the RCP3 slider type............................188
Correlation diagram of speed and loading capacity for the RCP3 table type ............................189
Push Force and Current-limiting Value......................................................................................190
Fault check and replacement of the cooling fan ........................................................................198
Example of Basic PCON Positioning Sequence........................................................................200
Recording of Parameters ..........................................................................................................203
Change History ..........................................................................................................................205
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.
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
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 operation 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
2
3
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
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).
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.
4
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.
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 Operation 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
operation manual of each unit to ensure the safety.
6
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 Operation Manual for each model.
Level Degree of Danger and Damage Symbol
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.
Danger
Warning
Caution
Notice
8
9
1. Overview
1.1 Introduction
This product is a dedicated RCP2 / RCP3 actuator controller that provides the same functions of the RCP2
controller as well as a set of new functions designed to achieve greater convenience and safety.
The product also provides a power-saving function in response to growing energy-saving needs.
The key features and functions are listed below.
z More positioning points
The standard type supports up to 64 points, while the extended types can handle up to 512 points. Availability
of more positioning points is ideal for production lines where many types of products are produced in small
volumes.
z Setting of zone output boundaries for each position in the position table
Before, zone output boundaries were set by parameters and therefore fixed. To add flexibility, new fields
have been added to the position table so that different boundaries can be set for each position.
This feature is useful in preventing contact with surrounding equipment and reducing the tact time, among
others.
z Separate acceleration/deceleration settings
Acceleration and deceleration are now set in separate fields of the position table.
Depending on the material or shape of the load, it is desirable to reduce shock and vibration when the
actuator stops.
Since acceleration and deceleration can be set differently, only the deceleration value can be reduced to
make the deceleration curve more gradual.
z Limitation of feed speed in test operation and adjustment
The feed speed to be used in test operation and adjustment can be limited for added safety.
z Power-saving measures
In general, pulse motors consume more holding current in standstill state than AC servo motors. This product
provides a power-saving means to support situations where the actuator must stand by for a long period.
1. Overview
When actually starting up your system or if you have encountered any problem, also refer to the operation
manuals for the actuator, teaching pendant, PC software and other components used with the system, in
addition to this manual.
This manual does not cover all possible operations other than normal operations, or unexpected events
such as complex signal changes resulting from use of critical timings.
Accordingly, you should consider items not specifically explained in this manual as “prohibited.”
* We have made every effort to ensure precision of the information provided in this manual. Should you find an
error, however, or if you have any comment, please contact IAI.
Keep this manual in a convenient place so it can be referenced readily when necessary.
1.2 How to Read the Model Specification
PCON - C - 56PI - NP - 2 - 0 - ABU - H
1. Overview
<Series>
<Type>
C: Positioner type with internal drive-
power cutoff relay
CG: Positioner type with external drive-
power cutoff relay
CF: High-output positioner type with internal
drive-power cutoff relay
<Actuator type>
[Motor flange size]
20P: 20, square
28P: 28, square
28SP: 28, square (RA3 type only)
42P: 42, square
56P: 56, square
86P: 86 square
[Encoder type]
I: Incremental
High-acceleration, loading
specification
Specified for connecting the
simple absolute unit
<Power-supply voltage>
0: 24 VDC
<I/O flat cable length>
0: No cable
2: 2 m
3: 3 m
5: 5 m
<Input/output signal pattern>
NP: NPN (Sink type)
PN: PNP (Source type)
DV: DeviceNet connection specification
CC: CC-Link connection specification
PR: PROFIBUS connection specification
CN: CompoNet connection specification
ML: MECHATROLINK connection
specification
EC: EtherCAT connection specification
EP: EtherNet/IP connection
specification
10
11
1. Overview
1.3 System Configuration
1.3.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)
Standard teaching
pendant
<CON-T, RCM-T>
Supplied flat
cable
Host system <PLC>
24-VDC I/O
power supply
PC software
(optional)
RS232C type <RCM-101-MW>
USB type <RCM 101-USB>
PC
Input power
supply
24 VDC
RCP2 actuator
External EMG switch
24 V
0 V
Caution: Connect one end of the EMG switch to the 24-V output of the input power supply and the
other end to the S1 terminal. Also short the S2 and EMG terminals using a jumper wire.
1.3.2 External Drive-Power Cutoff Relay Type (PCON-CG)
1. Overview
Standard teaching
pendant
<CON-t, RCM-T>
Host system <PLC>
Supplied flat
cable
24-VDC I/O
power supply
PC software
PC
(optional)
RS232C type <RCM-101-MW>
USB type <RCM 101-USB>
Input power
supply 24
VDC
RCP2 actuator
Motor drivepower cutoff
circuit
Safety relay
Contactor
12
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