PCON-CY Controller
Solenoid Valve Type
Operation Manual Ninth Edition
Fourteenth Edition
1
Please Read Before Use
Thank you for purchasing our product.
This Operation Manual explains the handling methods, structure and maintenance of this product, among others, providing the
information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of
the product.
The CD or DVD that comes with the product contains operation manuals for IAI products.
When using the product, refer to the necessary portions of the applicable operation manual by printing them out or displaying
them on a PC.
After reading the Operation Manual, keep it in a convenient place so that whoever is handling this product can reference it
quickly when necessary.
[Important]
• This Operation Manual is original.
• The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI shall assume
no responsibility for the outcome of any operation not specified herein.
• Information contained in this Operation Manual is subject to change without notice for the purpose of product
improvement.
• If you have any question or comment regarding the content of this manual, please contact the IAI sales office near
you.
• Using or copying all or part of this Operation Manual without permission is prohibited.
• The company names, names of products and trademarks of each company shown in the sentences are registered
trademarks.
CAUTION
1. Use Environment
PCON controllers can be used in an environment corresponding to 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.
skrameRledoM
PC software (with RS232C
communication cable)
PC software (with USB communication
cable)
Teaching pendant RCM-T
Simple teaching pendant RCM-E
Data setting unit RCM-P
RCM-101-MW
RCM-101-USB
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. Using Rotary Actuators in Multi-rotation Specification
Rotary actuators of multi-rotation specification models can be set to operate in the multi-rotation mode or
limited-rotation mode using a parameter.
4.1 Note
Pay attention to the PIO pattern parameter setting for the following controllers.
Each controller does not support relative coordinate specification in the PIO pattern specified below:
[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25)
[2] PCON-CY: PIO pattern = 0 (User parameter No. 25)
4.2 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 Differences from Air Cylinders in Control Functions.....................................................................................10
1.3 How to Read Model Name ........................................................................................................................... 12
1.4 System Configuration...................................................................................................................................13
1.5 Steps from Unpacking to Adjustment by Trial Operation..............................................................................14
1.6 Warranty.......................................................................................................................................................16
1.6.1 Warranty Period................................................................................................................................ 16
1.6.2 Scope of Warranty............................................................................................................................ 16
Honoring the Warranty......................................................................................................................
1.6.3
1.6.4 Limited Liability..................................................................................................................................16
1.6.5 Conditions of Conformance with Applicable Standards/Regulations, Etc.,
and Applications................................................................................................................................17
1.6.6 Other Items Excluded from Warranty................................................................................................ 17
2. Specifications.................................................................................................................................18
2.1 Basic Specifications .....................................................................................................................................18
2.2 Name and Function of Each Part of the Controller.......................................................................................19
2.3 External Dimensions ....................................................................................................................................20
3. Installation and Wiring....................................................................................................................21
3.1 Installation Environment............................................................................................................................... 21
3.2 Supplied Voltage..........................................................................................................................................21
3.3 Noise Elimination Measures and Grounding ................................................................................................ 22
3.4 Heat Radiation and Installation ....................................................................................................................23
3.5 External Connection Diagram ......................................................................................................................24
3.6 Wiring the Power Supply..............................................................................................................................25
3.7 Wiring the Brake Forced-release Switch......................................................................................................25
3.8 Wiring the Emergency Stop Circuit ..............................................................................................................26
3.8.1 Cutting Off the Drive Signal (Standard) ............................................................................................26
3.8.2 Cutting Off the Motor Drive Power .................................................................................................... 28
3.9 Connecting the Actuator...............................................................................................................................29
3.9.1 Motor Relay Cable ............................................................................................................................ 29
3.9.2 Encoder Relay Cable........................................................................................................................30
3.10 Connecting the I/O Flat Cable......................................................................................................................31
3.11 Connecting the Communication Cable.........................................................................................................32
16
4. Position Table Settings ..................................................................................................................33
4.1 Details of the Position Table ........................................................................................................................33
4.2 Notes on the ROBO Gripper ........................................................................................................................38
5. Operation Using I/O Signals ..........................................................................................................40
5.1 Interface Circuit............................................................................................................................................40
5.1.1 External Input Specifications.............................................................................................................40
5.1.2 External Output Specifications..........................................................................................................41
5.1.3 Recognition of Input Signals .............................................................................................................42
5.2 Proximity Switch Type..................................................................................................................................43
5.2.1 Explanation of I/O Signals.................................................................................................................43
5.2.2 Timings after Power On ....................................................................................................................45
Steps from Initial Startup to Actuator Adjustment........................................................................45
Normal Operating Procedure ......................................................................................................46
5.2.5 Positioning Operation .......................................................................................................................51
z Meaning of Position Detection Output Signals (LS0, LS1, LS2)..................................................52
z Notes on Setting the Positioning Band........................................................................................52
z Speed Change during Movement................................................................................................53
z Pausing during Movement...........................................................................................................54
z Forced Return in Case of Emergency .........................................................................................54
5.3 Standard Type .............................................................................................................................................55
5.3.1 Explanation of I/O Signals.................................................................................................................55
5.3.2 Timings after Power On .................................................................................................................... 57
z Steps from Initial Startup to Actuator Adjustment........................................................................57
z Normal Operating Procedure ......................................................................................................58
5.3.3 Position Table and Parameter Settings Required for Operation .......................................................60
Test Operation ............................................................................................................................60
Safety speed during manual feed .....................................................................................................60
Speed override for move commands from the PLC .......................................................................... 60
Full-scale Operation ....................................................................................................................61
Power-saving when the standby time after power on is long ............................................................61
Power-saving when the standby time at the target position is long...................................................61
Complete signal output mode ...........................................................................................................61
5.3.4 Homing .............................................................................................................................................62
5.3.5 Positioning Operation .......................................................................................................................63
z Meaning of Positioning Complete Output Signals (PE0, PE1, PE2)............................................64
z Notes on Setting the Positioning Band........................................................................................64
z Speed Change during Movement................................................................................................65
z Pausing during Movement...........................................................................................................66
z Forced Return in Case of Emergency .........................................................................................66
z Constant Pitch Feed....................................................................................................................67
5.3.6 Zone Output Signal...........................................................................................................................69
5.3.7 Push-motion Operation .....................................................................................................................70
5.3.8 Examples of Tact Time Reduction Combining Zone Outputs and 3 Stop Points ..............................76
5.4 Power-saving Modes at Standby Positions .................................................................................................. 78
5.5 Using Rotary Actuators in Multi-rotation Specification..................................................................................81
5.5.1 How to Use .......................................................................................................................................81
6. Parameter Settings ........................................................................................................................82
6.1 Parameter List..............................................................................................................................................82
6.2 Detail Explanation of Parameters.................................................................................................................83
6.2.1 Parameters Relating to Actuator Stroke Range ................................................................................83
z Soft Limits (No.3/4 LIMM/LIML)...................................................................................................83
z Home Direction (No.5 ORG) .......................................................................................................83
z Home Offset (No.22 OFST).........................................................................................................84
z Zone Limits (1: No. 1/2 ZONM/ZONL 2: No. 23/24 ZNM2/ZNL2)................................................ 84
6.2.2 Parameters Relating to Actuator Operating Characteristics..............................................................85
z Default Speed (No.8 VCMD) .......................................................................................................85
z Default Acceleration/Deceleration (No.9 ACMD).........................................................................85
z Default Positioning Band (In-position) (No.10 INP) .....................................................................85
z Current-limiting Value during Homing (No.13 ODPW) ................................................................85
z Current-limiting Value at Standstill after Positioning (No.12 SPOW)...........................................85
z Speed Override (No.46 OVRD)...................................................................................................85
z Default Direction of Excited Phase Signal Detection (No.28 PHSP) ...........................................86
z Excited Phase Signal Detection Time (No.29 PHSP)..................................................................86
z Automatic Servo-off Delay Time (No.36 ASO1/ No.37 ASO2/ No.38 ASO3) ..............................87
z Default Standstill Mode (No.53 CTLF) ........................................................................................87
z Push Speed (No.34 PSHV) .........................................................................................................88
z Push-motion Completion Judgment Time (No.6 PSWT) .............................................................88
z Enable Function (No.42 FPIO) ....................................................................................................89
z Home Check Sensor Input Polarity (No.43 AIOF) .......................................................................89
z Home Sensor Input Polarity (No. 18, LS) ....................................................................................90
z Ball Screw Lead (No. 77, LEAD) .................................................................................................90
z Axis Operation Type (No. 78, ATYP) ..........................................................................................90
z Rotational Axis Mode Selection (No. 79, ATYP) .........................................................................90
Push Speed (No.34 PSHV) .........................................................................................................88
Push-motion Completion Judgment Time (No.6 PSWT) .............................................................88
Enable Function (No.42 FPIO) ....................................................................................................89
Home Check Sensor Input Polarity (No.43 AIOF) .......................................................................89
Home Sensor Input Polarity (No. 18, LS) ....................................................................................90
Ball Screw Lead (No. 77, LEAD) ................................................................................................. 90
Axis Operation Type (No. 78, ATYP) ..........................................................................................90
Rotational Axis Mode Selection (No. 79, ATYP) .........................................................................90
Shortcut Selection for Rotational Axis (No. 80, ATYP)................................................................91
Absolute Unit (No. 83, ETYP)......................................................................................................91
6.2.3 Parameters Relating to External Interface ........................................................................................92
PIO Pattern Selection (No.25 IOPN) ...........................................................................................92
Positioning Complete Signal Output Mode (No.39FPIO) ............................................................92
Servo-on Input Disable Selection (No.21 FPIO)..........................................................................93
SIO Communication Speed (No.16 BRSL)..................................................................................93
Minimum Delay Time for Slave Transmitter Activation (No.17 RTIM) .........................................93
Silent Interval Multiplication Factor (No.45 SIVM) .......................................................................93
6.2.4 Servo Gain Adjustment .....................................................................................................................94
Servo Gain Number (No.7 PLG0) ...............................................................................................94
Speed Loop Proportional Gain (No.31 VLPG).............................................................................94
Speed Loop Integral Gain (No.32 VLPT) ....................................................................................95
Torque Filter Time Constant (No.33 TRQF)................................................................................95
7. Troubleshooting .............................................................................................................................96
7.1 What to Do When A Problem Occurs...........................................................................................................96
7.2 Alarm Level Classification ............................................................................................................................97
7.3 Alarms, Causes and Actions ........................................................................................................................ 98
(1) Operation Cancellation Alarms....................................................................................................98
(2) Cold Start Alarms ...................................................................................................................... 101
7.4 Messages Displayed during Teaching Pendant Operation ........................................................................104
7.5 Common Problems and Recommended Actions .......................................................................................106
I/O Signals Cannot Be Sent or Received to/from the PLC. .......................................................106
The ALM Lamp Illuminates after the Power Is Turned On.........................................................106
After Turning On the Power, the SV Lamp Does Not Illuminate upon Servo-on Signal Input....106
With an Actuator Installed in Vertical Orientation, Positioning Completes Prematurely. ...........107
With an Actuator Installed in Vertical Orientation, Noise Generates during Downward Movement.
107
Vibration Occurs when the Actuator Is at Standstill...................................................................107
The Actuator Overshoots while Decelerating to a Stop.............................................................107
Stopped Position Sometime Deviates from the Home Position or Target Position....................107
The Actuator Moves Slow during Push-motion Operation.........................................................107
The Actuator Moves Only a Half, or as Much as Twice, the Specified Travel. ..........................107
A Servo Error Occurred while the ROBO Gripper Was Moving.................................................108
The Actuator Malfunctions when the Servo Is Turned On after Turning On the Power............. 109
The SV Lamp Blinks..................................................................................................................109
* Appendix...........................................................................................................................................110
List of Specifications of Connectable Actuators ....................................................................................................110
Correlation diagram of speed and load capacity for the slider type (motor-straight type) ...................................122
Correlation diagram of speed and load capacity for the slider type (motor-reversing type) ................................123
Correlation diagram of speed and load capacity for the standard rod type ...........................................................124
Correlation diagram of speed and load capacity for the single-guide type ............................................................125
Correlation diagram of speed and load capacity for the double-guide type...........................................................126
Correlation diagram of speed and load capacity for the dustproof/splash-proof type ............................................127
Correlation diagram of speed and load capacity for the RCP3 slider type ............................................................128
Correlation diagram of speed and load capacity for the RCP3 table type .............................................................129
Push Force and Current-limiting Value..................................................................................................................130
Position Table Record ........................................................................................................................................... 137
Parameter
Change History
Record .................................................................................................................................................138
139......................................................................................................................................................
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
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.)
Do not use the product outside the specifications. Failure to do so may
considerably shorten the life of the product.
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
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.
1
No.
Operation
Description
Description
2 Transportation When carrying a heavy object, do the work with two or more persons or
utilize equipment such as crane.
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.
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.
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.
Do not step or sit on the package.
Do not put any heavy thing that can deform the package, on it.
When using a crane capable of 1t or more of weight, have an operator
who has qualifications for crane operation and sling work.
When using a crane or equivalent equipments, make sure not to hang a
load that weighs more than the equipment’s capability limit.
Use a hook that is suitable for the load. Consider the safety factor of the
hook in such factors as shear strength.
Do not get on the load that is hung on a crane.
Do not leave a load hung up with a crane.
Do not stand under the load that is hung up with a crane.
3 Storage and
Preservation
The storage and preservation environment conforms to the installation
environment. However, especially give consideration to the prevention of
condensation.
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.
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.
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.
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
No.
Operation
Description
4 Installation
and Start
Description
(2) Cable Wiring
Use our company’s genuine cables for connecting between the actuator
and controller, and for the teaching tool.
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.
Perform the wiring for the product, after turning OFF the power to the unit,
so that there is no wiring error.
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.
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.
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
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.
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).
Perform Class D Grounding (former Class 3 Grounding with ground
resistance 100 or below).
3
No.
4 Installation
Operation
Description
and Start
Description
(4) Safety Measures
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.
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.
Make sure to install the emergency stop circuit so that the unit can be
stopped immediately in an emergency during the unit operation.
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.
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.
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.
Take the measure so that the work part is not dropped in power failure or
emergency stop.
Wear protection gloves, goggle or safety shoes, as necessary, to secure
safety.
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.
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 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.
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.
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.
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.
Place a sign “Under Operation” at the position easy to see.
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
No.
Operation
Description
Description
6 Trial Operation 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.
After the teaching or programming operation, perform the check operation
one step by one step and then shift to the automatic operation.
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.
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.
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
Check before starting the automatic operation or rebooting after operation
stop that there is nobody in the safety protection fence.
Before starting automatic operation, make sure that all peripheral
equipment is in an automatic-operation-ready state and there is no alarm
indication.
Make sure to operate automatic operation start from outside of the safety
protection fence.
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.
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.
5
No.
8 Maintenance
Operation
Description
and Inspection
Description
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.
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.
When the work is to be performed inside the safety protection fence,
basically turn OFF the power switch.
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.
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.
Place a sign “Under Operation” at the position easy to see.
For the grease for the guide or ball screw, use appropriate grease
according to the Operation Manual for each model.
Do not perform the dielectric strength test. Failure to do so may result in a
damage to the product.
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.
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.
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
Do not modify, disassemble, assemble or use of maintenance parts not
specified based at your own discretion.
10 Disposal When the product becomes no longer usable or necessary, dispose of it
properly as an industrial waste.
When removing the actuator for disposal, pay attention to drop of
components when detaching screws.
Do not put the product in a fire when disposing of it.
The product may burst or generate toxic gases.
11 Other 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.
See Overseas Specifications Compliance Manual to check whether
complies if necessary.
For the handling of actuators and controllers, follow the dedicated
operation manual of each unit to ensure the safety.
6
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
7
8
1. Overview
1.1 Introduction
As a dedicated controller for our RCP2 and RCP3 actuators, this controller becomes smaller and more affordable and
incorporates a new set of features to offer greater convenience and safety, while maintaining the functions of the RCP2
controller.
This controller also provides power-saving functions to address the growing need for saving energy.
The key features and functions of this controller are summarized below.
z Limited I/O positioning points (3 points)
The I/O signals are designed to function in the same manner as those of air cylinders. Two operation types are supported.
The movement complete signals have different meanings in each type.
• Proximity switch type --- Each movement complete signal works as an auto switch. Even when positioning operation is
not performed, a movement complete signal is output once the specified position is passed.
• Standard type --- A movement complete signal is output only when positioning operation has completed following
a move command.
* The controller is configured to support the proximity switch type before shipment.
z Separate zone output limits for each of 3 positions (rear end, intermediate point, front end)
Before, the zone output limits were set by parameters and thus fixed to a certain width for all positions. To increase
flexibility, setting fields have been added to the position table to allow different limits to be set for each position.
This function is useful in preventing contact with peripheral equipment or reducing the tact time.
z Independent acceleration and deceleration settings
The position table now has separate fields for acceleration and deceleration.
The purpose of this change is to prevent works made of certain materials or having certain shapes from receiving impact or
vibration when the actuator decelerates to a stop.
By reducing the deceleration setting, a more gradual deceleration curve can be achieved.
z Limitation of feed speed during adjustment by test operation
The feed speed during adjustment by test operation can be limited to ensure safety.
z Power-saving measures
In general, pulse motors consume more holding current in standstill state than AC servo motors. Accordingly, this controller
provides power-saving means by assuming situations where the motor is used in applications requiring a long standby
time.
1. Overview
When actually starting your system or if you have encountered any problem, also refer to the manuals for the actuator,
teaching pendant, PC software and/or any other component you are using, in addition to this manual.
This manual does not cover all possible deviations from normal operations or unexpected phenomena such as complex
signal changes resulting from critical timings.
Therefore, the reader should assume that items not described in this manual are “not permitted,” as a rule.
* This manual has been prepared with the utmost attention to ensure accuracy and completeness. However, there may still
be inaccuracies and omissions. Should you find any inaccurate description or if you have any comment, please contact
IAI.
Keep this manual in a convenient place so that you can easily reference it whenever necessary.
9
1.2 Differences from Air Cylinders in Control Functions
For those of you who have been using air cylinders and have never used motorized cylinders before, this section gives a brief
explanation of how this controller is different from air cylinders.
Read the following information and implement controls appropriate for your system.
1. Overview
Drive method Air pressure by solenoid valve control. Ball screw or timing belt drive using a pulse motor.
Target position setting Mechanical stopper (including shock
Target position
detection
Speed setting Adjustment by a speed controller. Entry of a feed speed in the “Speed” field of the position
Acceleration/
deceleration setting
Item Air cylinder PCON
Entry of a coordinate value in the “Position” field of the
absorber).
Installation of a reed switch or other
external detection sensor.
In accordance with the load, air supply
volume, and speed controller/solenoid
valve performance.
position table.
A value can be entered by keying in a number from a
PC/teaching pendant, or by moving the actuator to a
desired position and then reading the achieved position
directly.
Example) Example of entry of “400 mm” stroke
Position No. Position
0 5 (mm), rear end
1 400 (mm), front end
2 200 (mm), intermediate point
Judgment based on internal coordinates determined by
the position information received from the position
detector (encoder).
No external detection sensor is required.
table (unit: mm/sec).
Note that the rated speed is set automatically as the
default feed speed.
Entry in the “Acceleration” and “Deceleration” fields of the
position table (minimum setting unit: 0.01 G).
Reference: 1 G = Gravitational acceleration
Note that the rated acceleration and deceleration are set
automatically as the default acceleration and
deceleration.
Desired values can be set in fine steps to achieve gradual
acceleration/deceleration curves.
10
Acceleration
Start position
of movement
The greater the set value, the steeper the curve
becomes. On the other hand, the smaller the set value,
the more gradual the curve becomes.
Deceleration
End
position
Item Air cylinder PCON
r
Position check upon
power on
Judgment using a reed switch or other
external detection sensor.
When the power is turned on, mechanical coordinates are
not stored in the controller and thus the current position is
not yet determined.
For this reason, a rear end move command must be
executed after the power has been turned on, in order to
establish coordinates.
The actuator performs homing first, and then moves to
the rear end.
[1]
[2]
[3]
-on position
Powe
Rear end
Home position
[1] The actuator moves toward the mechanical end on
the motor side at the homing speed.
[2] The actuator contacts the mechanical end, reverses
its direction, and stops temporarily at the home
position.
[3] The actuator moves to the rear end at the speed set
in the “Speed” field of the position table.
(Note) Make sure there is no obstacle along the homing
path.
1. Overview
11
1.3 How to Read Model Name
<Series>
1. Overview
<Type>
CY: Dedicated controller for 3-point
<Actuator characteristics>
[Motor flange size]
20P: 20, square
28P: 28, square
28SP: 28, square (RA3 type only)
42P: 42, square
56P: 56, square
[Encoder type]
I: Incremental
positioning by I/Os
High-acceleration loading
specification
Specifiation 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
<I/O signal type>
NPxxNPN [Sink]
PNxxPNP [Source]
12
1.4 System Configuration
This controller performs positioning to 3 points (rear end, intermediate point, front end) via a PLC and I/O signals.
Standard teaching
pendant
Host system <PLC>
PCON-CY controller
Flat cable
<supplied with
the controller>
* If a PLC will not be used,
Cable length: 2 m
disable the servo-on
input by the applicable
parameter.
24-VDC I/O
power supply
1. Overview
RS232C type
USB type
PC software
(optional)
PC
Input power
supply
24 VDC
Brake forced-release
switch
External EMG switch
RCP2 actuator
Power-supply
terminal block
Caution: If the actuator is not equipped with a brake, the BK terminal need not be connected.
13
1.5 Steps from Unpacking to Adjustment by Trial Operation
If you are using this controller for the first time, refer to the steps explained below and perform the specified tasks carefully by
making sure you check all necessary items and connect all required cables.
1.
1. Overview
Should you find any of the following items missing or of a wrong model type, please contact your IAI sales agent.
z Controller z Actuator z I/O flat cable z Motor cycle z Encoder cable
PCON-CY CB-PACY-PIO *** CB-RCP2-MA *** CB-RCP2-PA ***
z Operation manual
<Options>
z Teaching pendant z PC software
RCM-T (standard) RS232C type <RCM-101-MW>
RCM-E (simple) USB type <RCM-101-USB>
RCM-P (data setting) (Each software program comes with a cable.)
2.
[1] Affix the actuator and install the robot hand → Refer to the operation manual for your actuator.
[2] Install the controller → Chapter 3, “Installation and Wiring”
3.
• Wire the 24-V power supply.
• Wire the brake forced-release switch (if the actuator is equipped with a brake).
• Connect the grounding wire to ground.
• Wire the emergency stop circuit and motor drive power supply.
• Connect the motor cable and encoder cable.
• Connect the I/O flat cable.
Checking the items in the package
Installation
Wiring/connection
4.
Confirm first that the emergency stop circuit is not actuated, and then supply the 24-V power.
If the monitor LED [SV/ALM] on the front face of the controller illuminates in orange for 2 seconds and then turns off, the
controller is normal.
If the [SV/ALM] illuminates in red, it means that an alarm is present.
In this case, connect a PC or teaching pendant and check the nature of the alarm, and remove the cause by referring to
Chapter 7, “Troubleshooting.”
5.
Set the MANU operation mode to [Teaching mode 1: Enable safety speed / Inhibit PIO] on the PC or teaching pendant.
In this condition, set appropriate values in parameter No. 25 (PIO pattern selection) and parameter No. 35 (Safety speed).
* The factory settings of PIC pattern and safety speed are “Standard type” and “100 mm/s or less,” respectively.
Turning on the power and checking for alarms
Setting a PIO pattern/safety speed
→ Chapter 6, “Parameter Settings”
14
Operating when the servo is ON
6.
Confirm that the slider or rod is not contacting a mechanical end.
If the slider or rod is contacting a mechanical end, move it away from the mechanical end.
If the actuator is equipped with a brake, move the actuator after turning ON the forced brake release switch to forcibly release
the brake.
At this time, be careful not to get your hand pinched or the robot hand damaged by the actuator dropping suddenly due to its
dead weight.
Turn ON the servo using the PC or teaching pendant.
If the actuator enters a servo lock state and the monitor LED [SV/ALM] on the front face of the controller illuminates in green,
the controller is normal.
1. Overview
7.
Confirm that the emergency cutoff circuit (or motor drive-power cutoff circuit) operates normally.
8.
Use the teaching pendant or PC to set a target position in the “Position” field of the position table (rear end, front end,
intermediate point).
* If any movement operation is started without setting a target position first, the message “No movement data” will be
displayed. Determine an appropriate target position by fine-tuning the work or robot hand.
* Once a target position is set, other items (speed, acceleration/deceleration, positioning band, etc.) will be set to their defaults
automatically. → Chapter 4, “Position Table Settings”
9.
Input a move command from the PLC to perform positioning.
If necessary, perform the following fine adjustments:
• Depending on the weight, material and/or shape of the work, vibration or noise may occur. If you notice undesirable vibration
or noise, lower the speed, acceleration and/or deceleration.
• You may also want to adjust the zone output signal limits and positioning band to prevent contact with peripheral equipment
or reduce the tact time.
• If push-motion operation will be performed, select optimal current-limiting value, push-motion completion judgment time and
push speed.
Confirming the safety circuit operation
→ Chapter 3, “Installation and Wiring”
Setting a target position
Adjustment by test operation
→ Chapter 4, “Position Table Settings”
→ Chapter 5, “Operation Using I/O Signals”
15
1.6 Warranty
1.6.1 Warranty Period
One of the following periods, whichever is shorter:
Elapse of 18 months after the shipment from IAI
Elapse of 12 months after the delivery to the specified location
1. Overview
1.6.2 Scope of Warranty
Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty
will be replaced or repaired free of charge:
(1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer.
(2) The breakdown or problem in question occurred during the warranty period.
(3) The breakdown or problem in question occurred while the product was in use for an appropriate purpose under the
(4) The breakdown or problem in question was caused by a specification defect or problem, or by the poor quality of
Note that breakdowns due to any of the following reasons are excluded from the scope of warranty:
conditions and environment of use specified in the operation manual and catalog.
our product.
[1] Anything other than our product
[2] Modification or repair performed by a party other than us (unless we have approved such modification or repair)
[3] Anything that could not be easily predicted with the level of science and technology available at the time of shipment
from our company
[4] A natural disaster, man-made disaster, incident or accident for which we are not liable
[5] Natural fading of paint or other symptoms of aging
[6] Wear, depletion or other expected result of use
[7] Operation noise, vibration or other subjective sensation not affecting function or maintenance
Note that the warranty only covers our product as delivered and that any secondary loss arising from a breakdown of our
product is excluded from the scope of warranty.
1.6.3 Honoring the Warranty
As a rule, the product must be brought to us for repair under warranty.
1.6.4 Limited Liability
[1] We shall assume no liability for any special damage, consequential loss or passive loss such as a loss of expected
profit arising from or in connection with our product.
[2] We shall not be liable for any program or control method created by the customer to operate our product or for the result
of such program or control method.
16
1.6.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications
(1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must
first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such
combination with our product conforms to the applicable standards, etc. In such a case we will not be liable for the
conformance of our product with the applicable standards, etc.
(2) Our product is for general industrial use. It is not intended or designed for the applications specified below, which
require a high level of safety. Accordingly, as a rule our product cannot be used in these applications. Contact us if you
must use our product for any of these applications:
[1] Medical equipment pertaining to maintenance or management of human life or health
[2] A mechanism or mechanical equipment intended to move or transport people (such as a vehicle, railway facility
or aviation facility)
[3] Important safety parts of mechanical equipment (such as safety devices)
[4] Equipment used to handle cultural assets, art or other irreplaceable items
(3) Contact us at the earliest opportunity if our product is to be used in any condition or environment that differs from
what is specified in the catalog or operation manual.
1.6.6 Other Items Excluded from Warranty
The price of the product delivered to you does not include expenses associated with programming, the dispatch of
engineers, etc. Accordingly, a separate fee will be charged in the following cases even during the warranty period:
[1] Guidance for installation/adjustment and witnessing of test operation
[2] Maintenance and inspection
[3] Technical guidance and education on operating/wiring methods, etc.
[4] Technical guidance and education on programming and other items related to programs
1. Overview
17
2. Specifications
2.1 Basic Specifications
Number of controlled axes 1 axis per unit
Power-supply voltage 24 VDC +10%/-10%
Power-supply capacity 2 A max.
Control method Field-weakening vector control (patent pending)
2. Specifications
Encoder resolution 800 P/rev
Positioning command
Backup memory
PIO interface 24-VDC insulation
LED indicator
Serial communication RS485, 1 channel (conforming to the Modbus protocol)
Encoder interface Incremental specification conforming to EIA RS-422A/423A
Forced release of electromagnetic brake 24 V is applied to the BK terminal on the power-supply terminal block.
Cable length
Dielectric strength
Environment Surrounding air temperature
Protection class Natural air cooling (IP20)
Weight 128 g or below
External dimensions 35 (W) x 120 (H) x 68 (D) mm
Specification item Description
YC-NOCPledoM
Separate commands for positioning to rear end, front end and
intermediate point
Position number data and parameters are stored in the nonvolatile
memory.
Serial EEPROM life: Approx. 100,000 times of rewriting
4 input points
• Front end move command
• Rear end move command
• Intermediate point move command
• Servo-on
6 output points
• Front end movement complete
• Rear end movement complete
• Intermediate point movement complete
• Ready (or zone output under the standard type)
• Homing complete
• *Alarm
SV (green) --- Whether or not the servo is on / ALM (red) --- Whether
or not an alarm is present.
Actuator cable: 20 m or shorter
I/O flat cable: 5 m or shorter
500 VDC 10 mΩ
0to40°C
Surrounding humidity 85% RH or below (non-condensing)
Surrounding environment Refer to 3.1 Installation Environment
Storage temperature
Storage humidity 90% RH or below (non-condensing)
Vibration resistance
-10 to 65°C
10 to 57 Hz in all X/Y/Z directions / Single amplitude: 0.035 mm
(continuous), 0.075 mm (intermittent)
18
2.2 Name and Function of Each Part of the Controller
Status indicator LED
PIO connector
Connects the PLC and PIO.
SIO connector
Connects the teaching
pendant/PC.
The model of the connected
actuator is indicated here.
Motor connector
Connects the motor cable.
SV (Green) --- Indicates whether or not the
servo is on.
If this LED is blinking, the
controller is in the automatic
servo-off mode.
ALM (Red) --- Indicates whether or not an
alarm is present.
The PIO pattern number is indicated
here.
If the PIO pattern is different for each
system, indicate the applicable PIO
pattern here to prevent confusion.
The I/O signal type is indicated here.
NPN --- Sink type
PNP --- Source type
Encoder connector
Connects the encoder cable.
2. Specifications
Power-supply terminal block
BK
MPI, MPO
24 V Positive side of the 24-VDC input power supply.
0 V Negative side of the 24-VDC input power supply.
EMG -
Model indication of the connected actuator type
The type, ball screw lead and stroke of the actuator are indicated. When connecting the cables, confirm that the actuator is
of the correct specifications.
Example of indication:
Connection terminal for the brake forced-release switch to be used when the actuator is equipped with a
brake. Connect the opposite side of the switch to 24 V.
Contacts for cutting off the motor drive power to achieve a safety level of safety category 1.
MPI and MPO connect to the input side and output side of the motor power supply, respectively.
(If these contacts are not used, connect them using a jumper cable. The controller is shipped with MPI and
MPO connected by a jumper cable.)
Connection terminal for the emergency stop circuit (for cutting of motor drive signals).
A common ground is used, so connect the opposite side of the emergency stop switch (or contacts) to the
positive side of the 24-VDC input power supply.
The actuator type is RA4C.
The ball screw lead is 5 mm.
The stroke is 200 mm.
19
2.3 External Dimensions
An external view and dimensions of this product are shown below.
2. Specifications
∅5
20
Loading...