IAI America RCP2-BA7U User Manual

Download

ROBO Cylinder

RCP2 Actuator

Belt-Drive Type

Eighth Edition

IAI America, Inc.

RCP2-BA6•BA6U•BA7•BA7U

Operating Manual

Please Read Before Use

Thank you for purchasing our product.

This Operating 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 Operating Manuals for IAI products. When using the product, refer to the necessary portions of the applicable instruction manual by printing them out or displaying them on a PC.

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

[Important]

� This Operating Manual is original. � This product is not to be used for any other purpose from what is noted in this Operating

Manual. IAI shall not be liable whatsoever for any loss or damage arising from the result of using the product for any other purpose from what is noted in the manual.

� The information contained in this Operating Manual is subject to change without notice for

the purpose of production improvement.

� If you have any question or finding regarding the information contained in this Operating

Manual, contact our customer center or our sales office near you.

� Using or copying all or a part of this Operating Manual without permission is prohibited. � The company names, names of products and trademarks of each company shown in the

sentences are registered trademarks.

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

Caution in Handling ........................................................................................................................8

International Standards Compliances ...........................................................................................10

Names of the Parts....................................................................................................................... 11

1. Specifications Check.............................................................................................................. 11

1.1 Checking the Product ..................................................................................................... 11

1.1.1 Parts ....................................................................................................... 11

1.1.2 Related Operating Manuals for the Each Controller Supported by this Product.... 11

1.1.3 How to Read the Model Nameplate ......................................................................12

1.1.4 How to Read the Model Number ...........................................................................12

1.2 Specification....................................................................................................................13

1.2.1 Speed .......................................................................................................13

1.2.2 Maximum Acceleration Speed and Load Capacity ................................................13

1.2.3 Relation of Speed and Maximum Load Capacity...................................................14

1.2.4 No. of Encoder Pulses...........................................................................................17

1.2.5 Positioning repeatability ........................................................................................17

1.2.6 Lost motion .......................................................................................................17

1.2.7 Load Moments of the Actuator and the Allowable Overhang Lengths ...................18

1.3 Options ........................................................................................................................... 19

1.3.1 Reversed-Home Type (Model: NM) ...................................................................... 19

1.4 Motor • Encoder Cables ..................................................................................................20

1.4.1 Motor Cables�(For PCON, RPCON and PSEL) .................................................... 20

1.4.2 Encoder Cables / Robot Encoder Cabl

es�(For PCON, RPCON and PSEL)

.........20

1.4.3 Motor • Encoder Integrated Cables�(For PMEC, PSEP and MSEP).....................21

2. Installation..............................................................................................................................22

2.1 Transportation.................................................................................................................22

2.2 Installation and Storage • Preservation Environment......................................................24

2.3 How to Install ..................................................................................................................25

2.3.1 General Rules on Installation ................................................................................25

2.3.2 Installing the Main Body ........................................................................................26

2.3.3 Mounting Surface ..................................................................................................27

2.3.4 Installing the Load to the Slider .............................................................................28

3. Connecting with the Controller ...............................................................................................29

4. Maintenance Inspection ......................................................................................................... 34

4.1 Inspection Items and Schedule .......................................................................................34

4.2 External Visual Inspection...............................................................................................34

4.3 Cleaning .........................................................................................................................34

4.4 Interior Inspection ...........................................................................................................35

4.5 Internal Cleaning.............................................................................................................36

4.6 Grease Supply to the Guides.......................................................................................... 37

4.6.1 Grease to

Apply.....................................................................................................

4.6.2 How to Apply the Grease.......................................................................................37

4.7 Drive Belt ........................................................................................................................38

4.7.1 Inspecting the Belt.................................................................................................38

4.7.2 Applicable Belt ......................................................................................................38

4.7.3 Checking and Adjusting the Belt Tension ..............................................................39

4.7.4 Replacing the Belt .................................................................................................41

4.8 Replacing the Motor........................................................................................................47

4.8.1 BA6/BA7 (Motor on the Top) .................................................................................47

4.8.2 BA6U/BA7U (Motor at the Bottom)........................................................................51

5. External Dimensions ..............................................................................................................57

5.1 RCP2-BA6/BA6U ............................................................................................................57

5.2 RCP2-BA7/BA7U ............................................................................................................58

6. How to use the home mark ....................................................................................................59

7. Life .........................................................................................................................................60

8. Warranty.................................................................................................................................61

8.1 Warranty Period ..............................................................................................................61

8.2 Scope of the Warranty ....................................................................................................61

8.3 Honoring the Warranty.................................................................................................... 61

8.4 Limited Liability ...............................................................................................................61

8.5 Conditions of Conformance with Applicable Standards/Regulations, Etc.,

and Applications..............................................................................................................62

8.6 Other Items Excluded from Warranty..............................................................................62

Change History............................................................................................................................. 63

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 1before the operation of this product.

Safety Precautions for Our Products

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

No.

Operation

Description

1 Model

Selection

� 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.

No.

Operation

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 Operating 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

No.

Operation

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.

4 Installation

and Start

(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 0.5mm2 (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).

No.

Operation

Description

4 Installation

and Start

(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.

No.

Operation

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.

No.

Operation

Description

8 Maintenance

and Inspection

� 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 Operating 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

Operating Manual of each unit to ensure the safety.

Alert Indication

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

Level Degree of Danger and Damage Symbol

Danger

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

Danger

Warning

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

Warning

Caution

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

Caution

Notice

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

Notice

Caution in Handling

1. Ensure use of the product in the specified conditions, environments and ranges.

Not keeping this may cause a drop in the performance or even a malfunction of the product.

2. Do not attempt to handle or operate the product in a way that is not described in the operating manual.

3. Use the products of IAI for the wiring between an actuator and a controller.

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

If the actuator is operated at a speed or acceleration/deceleration exceeding the allowable value, abnormal noise or vibration, failure, or shorter life may result.

5. Keep the load moment within the allowable value.

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

6. Do not apply any liquid with temperature lower than the ambient temperature of the installed actuator.

It may cause condensation inside the product, which may lead to malfunction.

7. Back and forth operation in a short distance may cause wear of grease.

If the actuators are moved back and forth continuously over a short distance of 30 mm or less, grease film may run out. As a guide, move the actuators back and forth repeatedly for around 5 cycles over a distance of 50mm or more after every 5,000 to 10,000 cycles. Keep using the actuators with the grease worn out may cause malfunction.

8. Make sure to attach the actuator properly by following this operating manual.

Using the product with the actuator not being certainly retained or affixed may cause abnormal noise, vibration, malfunction or shorten the product life. Turn the servo ON after separating the slider. from the mechanical end.

9. Turn the servo ON after putting the actuator or rod away from the� mechanical end.

Turning the servo ON near the mechanical end may disturb the magnetic pole phase detection, and may cause the magnetic pole unconfirmed error or the excitation detection error. Turn the servo ON after separating the slider, from the mechanical end.

International Standards Compliances

This actuator complies with the following overseas standards.

RoHS Directive CE Marking UL

� �

Names of the Parts

In this Operating Manual, the left and right sides are indicated by looking at the actuator from the motor end, with the actuator placed horizontally, as shown in the figure below.

�

• BA6/BA7 (Motor on the Top)

Right Side

Front

<Opposite

Motor End>

Front Cover

Side Cover

Base

Motor Cover

Slider

Left Side

Motor End

Belt Cover

Motor Cap

Rear Cover

Actuator Cable

�

• BA6U/BA7U (Motor at the Bottom)

�

Right Side

Front Cover

Side Cover

Base

Motor Cover

Slider

Left Side

Motor End

Rear Cover

Bracket Cover

Front

<Opposite

Motor End>

Motor Cap

Belt Cover

Actuator Cable

�

1. Specifications Check

1.1 Checking the Product

The standard configuration of this product is comprised of the following parts. See the component list for the details of the enclosed components. If you find any fault or missing parts, contact your local IAI distributor.

1.1.1 Parts

No. Name Model number Quantity Remarks

1 Actuator

Refer to “How to Read the Model Nameplate” and “How to Read the Model Number.”

Accessories

Motor • encoder cables

(Note1)

1set

3 Home mark sticker 1

4 First Step Guide 1

5 Operating Manual (DVD) 1

6 Safety Guide 1

Note1 The motor • encoder cables differ between the standard model and robot cable.

[Refer to 1.4, “Motor • Encoder Cables.”]

1.1.2 Related Operating Manuals for the Each Controller Supported by this Product

No. Name Control No.

Operating Manual for PCON�C/CG/CF Controller

ME0170

Operating Manual for PCON�CA/CFA Controller

ME0289

Operating Manual for PCON�CY Controller

ME0156

Operating Manual for PCON�SE Controller

ME0163

Operating Manual for PCON�PL/PO Controller

ME0164 6 Operating Manual for PSEL Controller ME0172 7 Operating Manual for MEC Controller ME0245 8 Operating Manual for PSEP/ASEP Controller ME0216 9 Operating Manual for MSEP Controller ME0299

10 Operating Manual for ROBONET ME0208 11

Operating Manual for RC PC Software IA�101�X-MW/IA-101-X-USBMW

ME0154

Operating Manual for RC PC Software RCM�101�MW/RCM�101�USB

ME0155

13 Operating Manual for MEC PC Software ME0248 14

Operating Manual for Teaching Pendant CON�T, CON-TG

ME0178

15 Operating Manual for Teaching Pendant SEL-T, SEL-TD, SEL-TG ME0183 16

Operating Manual for Touch Panel Teaching CON�PTA, CON-PDA, CON-PGA

ME0227

17 Operating Manual for Touch Panel Teaching CON-PT, CON-PD, CON-PG ME0295 18 Operating Manual for Touch Panel Teaching SEP-PT ME0217 19 Operating Manual for Easy Type Teaching Pendant RCM-E ME0174 20 Operating Manual for Data Input Pendant RCM-P ME0175 21 Operating Manual for Touch Panel Display RCM-PM-01 ME0182

1. Specications Check

1.1.3 How to Read the Model Nameplate

1.1.4 How to Read the Model Number

RCP2BA6I42P54500P1SNM



Note 1 Identification for IAI use only : It may be displayed for IAI use. It is not a code to show the

model type.

Series

<Type>

BA6: Main Body Width

58mm, Belt Type Motor on the Top Type

BA6U: Main Body Width

58mm, Belt Type Motor at the Bottom Type

BA7: Main Body Width

68mm, Belt Type Motor on the Top Type

BA7U: Main Body Width

68mm, Belt Type Motor at the Bottom Type

I : Incremental

42P : Pulse Motor 42�

<Lead>

54 : 54mm or equivalent

Model

Serial numbe

MODEL RCP2-BA6-I-42P-54-500-P1-S

SERIAL No.800061910 MADE IN JAPAN

Identification for IAI use only

(Note1)

NM : Reversed-Home Type

N : None P : 1m S : 3m M : 5m X�� : Length specification

(Example: X07=7m)

R�� : Robot cable

(Example: R05=5m)

P1 : PCON

RPCON PSEL

P2 : PMEC

PSEP MSEP

<Stroke> [Refer to 5. ”

External Dimensions”]

1.2 Specification

1.2.1 Speed

Speed limits (Unit: mm/s) �

Type Lead [mm] Maximum Speed [mm/s]

BA6/BA6U 1000 BA7/BA7U

54mm or

equivalent

1500

Caution: Use the product with the movement speed of 100mm/s or more, otherwise it may

cause vibration or noise in low speed operation.

1.2.2 Maximum Acceleration Speed and Load Capacity

Type Lead [mm] Maximum Acceleration [G]

Maximum Load

Capacity [kg]

BA6/BA6U 4 BA7/BA7U

54mm or

equivalent

0.5 8

Caution: Do not set speeds and accelerations/decelerations equal to or greater than the

respective ratings. Doing so may result in vibration, failure or shorter life.

1. Specications Check

1.2.3 Relation of Speed and Maximum Load Capacity

The load capacity is the value when the actuator is operated at the Max. Acceleration/Deceleration rate of 0.5G. The position gain in the parameters at the delivery is set to 10. If setting the position gain to 20, even though the maximum load capacity is decreased, the cycle time will be shortened by 0.3seconds.

Shown below is the graph of the load capacity for each speed.

0 250 500 750 1000 1250 1500 1750

Speed

mm / s

Load capacity

Position Gain:20

Position Gain:10 default at delivery)

RCP2-BA6/BA6U

0 250 500 750 1000 1250 1500 1750

Position Gain:10 default at delivery)

Position Gain:20

RCP2-BA7/BA7U

Load capacity kg

Speed

mm / s

The way to change the position gain differs depending on the controller.

Shown below is how to change it by using the PC software for example. For the details of how to change by using the teaching pendant, refer to the operating manual of the teaching pendant corresponding to the controller.

(1) PCON, RPCON, PSEP Controller

Change is to be made using the RC PC Software.

1) Select [Parameter] � [Edit] in the main menu

2) Input the password. The default password is set as [5119].

3) Select the axis number in the axis select window and click [OK].

4) For PCON and RPCON, change the setting in User Parameter No. 7: Servo gain selection from [1] to [3].

For PSEP, change the setting in User Parameter No. 3: Servo gain selection from [1] to [3]. (For PCON, RPCON and PSEP Controllers, Servo gain selection: 3 is equivalent to Position Gain:

20.)

5) Select [Parameter] � [Transmits to a controller] in the main menu.

6) Select the axis number in the axis select window and click [OK]. The parameters are sent to the controller.

(2) PMEC Controller

Change is to be made using MEC PC Software.

1) Click [Maintenance] in the main menu.

2) Select [Parameter] in Maintenance window.

3) Change the setting in User Parameter No. 3: Servo gain selection from [1] to [3]. (Servo gain selection: 3 is equivalent to Position Gain: 20.)

4) Click [Store to MEC]. The parameters are sent to the controller.

255

1000

0. 50

1. Specications Check

(3) PSEL Controller

Change to be made using the X-SEL PC Software.

1) Select [Parameter] � [Edit] in the main menu

2) Change Axis Parameter No. 60: Position Gain [1/s] from 10 to 20.

click (Transfer to Controller).

The parameters are sent to the controller.

4) Once the parameter transfer is complete, a confirmation message saying [Do you want to write to Flash ROM?] comes up. Click [Yes].

5) After writing to flash ROM, a confirmation message saying [Do you want to reboot the controller?] comes up. Click [Yes]. The controller will be restarted.

1.2.4 No. of Encoder Pulses

800

1.2.5 Positioning repeatability

±0.1mm

* The values shown above are the accuracy at the delivery from the factory. It does not include the

consideration of time-dependent change as it is used.

1.2.6 Lost motion

0.1mm or less

* The values shown above are the accuracy at the delivery from the factory. It does not include the

consideration of time-dependent change as it is used.

1. Specications Check

1.2.7 Load Moments of the Actuator and the Allowable Overhang Lengths

� Allowable load moments

Model Ma Mb Mc

BA6/BA6U

8.9N�m(0.91Kgf�m) 12.7N�m(1.29Kgf�m) 18.6N�m(1.9Kgf�m)

BA7/BA7U

13.8N�m(1.41Kgf�m) 19.7N�m(2.01Kgf�m) 29.0N�m(2.96Kgf�m)

� Allowable overhang lengths

Model Ma directions Mb directions Mc directions BA6/BA6U 150mm or less 150mm or less 150mm or less BA7/BA7U 150mm or less 150mm or less 150mm or less

The allowable overhang lengths are based on a configuration where the center of the load mounted on the actuator corresponds to the center of the overhang length.

Caution: � Keep the load moment within the allowable value. If the actuator is operated

under a load equal to or greater than the allowable load moment, abnormal noise or vibration, failure, or shorter life may result. In an extreme case, it may cause flaking on the guide. Do not apply any liquid with temperature lower than the ambient temperature of the actuator installation. It may cause condensation inside the product, which may lead to malfunction.

� In case of using the actuator as the Y-axis in a combination of one-sided X-Y,

save the ratings of Ma and Mc moments in 1/2 or less because the base body becomes easy to deform.

Directions of the moment forces Directions of the allowable overhangs

Mb, Mc directions

Ma direction

1.3 Options

1.3.1 Reversed-Home Type (Model: NM)

The home position is normally set on the motor side, however, the home direction can be set opposite by option if a reversed type is required due to such a reason as the layout of the system.

1. Specications Check

1.4 Motor • Encoder Cables

1.4.1 Motor Cables(For PCON, RPCON and PSEL)

* The motor cable is a robot cable as standard.

CB-RCP2-MA��

Width

Electric

Wire Color

Signal Name

Pin No.

Signal Name

Electric

Wire Color

Width

Orange A_ A1 1 A Yellow

Gray VMN A2 2 VMM Gray

White B_ A3 3 A_ Orange

Yellow A B1 4 B Yellow (Green)

Pink VMM B2 5 VMM Pink

I-1318119-3

(AMP)

Yellow (Green) B B3 6 B_ White

SPL-06V

(JST)

1.4.2 Encoder Cables / Robot Encoder Cables(For PCON, RPCON and PSEL)

CB-RCP2-PB��/CB-RCP2-PB��-RB

Electric Wire Color

Width

Standard Cable Robot Cable

Signal

Name

Pin No.

Blue (Red1) Orange (Black2) LS+ 16 Electric Wire Color

White Orange (Red2) LS- 15

Pin No.

Signal Name

Standard Cable Robot Cable

Width

Red Orange (Black1) BK+ 14 1 ENA Brown Light Gray (Black1)

Gray Orange (Red1) BK- 13 2 ENA



Green Light Gray (Red1)

Brown Light Gray (Black1) ENA 12 3 ENB Purple White (Black1)

Green Light Gray (Red1) ENA



11 4 ENB



Pink White (Red1)

Purple White (Black1) ENB 10 5 - - -

Pink White (Red1) ENB



9 6 - - -

- - - 8 7 - - -

Yellow Yellow (Black1) VPS 7 8 - - -

Orange Pink (Red1) VBB 6 9 GND Blue Pink (Black1)

Blue Pink (Black1) GND 5 10 VBB Orange Pink (Red1)

- - (N.C) 4 11 VPS Yellow Yellow (Black1)

- - (N.C) 3 12 - - -

- - (N.C) 2 13 LS+ Blue (Red1) Orange (Black2)

PHDR-16VS

(JST)

Ground Ground F.G 1 14 LS- White Orange (Red2)

15 - - - 16 BK+ Red Orange (Black1) 17 BK- Gray Orange (Red1) 18 F.G Ground Ground

XMP-18V

(JST)

(20) (8)

(15)

CN3

C N

(φ8)

(28)

(14)

(20)

Min. Bending Radius = 50mm or more (Movable Use)

Controller Side Mechanical Side

(Front View) (Front View)

Ground wire

Shield wire

C N

CN4

Min. Bending Radius = 50mm or more (Movable Use)

(8)(5)

(φ9)

(35)

(15)

(13)

(Front View) (Front View)

(18)

Controller Side Mechanical Side

1.4.3 Motor • Encoder Integrated Cables(For PMEC, PSEP and MSEP)

CB-PSEP-MPA��

Electric Wire Color Signal Name Pin No. Pin No Signal Name Electric Wire Color

Black �A 1 1 �A Black White VMM 2 2 VMM White

Red �B 4 3 �B Red Green VMM 5 4 VMM Green Brown �A 3 5 �A Brown Yellow �B 6 6 �B Yellow

Electric Wire Color Signal Name Pin No.

Orange BK+ 16 9 BK+ Orange

Gray BK- 17 10 BK- Gray

- - 5 11 - -

- - 6 12 - -

Black LS+ 13 7 LS+ Black

Brown LS- 14 8 LS- Brown

White A+ 1 13 A+ White

Yellow A- 2 14 A- Yellow

Red B+ 3 15 B+ Red Green B- 4 16 B- Green

White VCC 10 17 VCC White

Yellow VPS 11 18 VPS Yellow

Red GND 9 19 GND Red Green (Reserved) 12 20 (Reserved) Green

- - 15 21 - -

- - 7 22 - -

- - 8 23 - -

Shield FG 18 24 FG Shield

Controller Side Mechanical Side

1. Specications Check

2. Installation

2.1 Transportation

[1] Handling of the Robot

Unless otherwise specified, the actuators are packaged individually.

(1) Handling the Packed Unit

� Do not damage or drop. The package is not applied with any special treatment that enables it to

resist an impact caused by a drop or crash.

� An operator should never attempt to carry a heavy package on their own. Also, use an

appropriate way for transportation.

� Keep the unit in a horizontal orientation when placing it on the ground or transporting. Follow the

instruction if there is any for the packaging condition.

� Do not step or sit on the package. � Do not put any load that may cause a deformation or breakage of the package.

(2) Handling the Actuator After Unpacking

� Do not attempt to carry the actuator by holding a cable or move it by pulling a cable. � Hold the base part and the bracket when transporting the actuator main body. � Do not hit or drop the actuator during transportation. � Do not give any excessive force to any of the sections in the actuator.

[2] Handling in the Assembled Condition

This is the case when the product is delivered from our factory under a condition that it is assembled with other actuators. The combined axes are delivered in a package that the frame is nailed on the lumber base. The sliders are fixed so they would not accidently move. The actuators are also fixed so the tip of it would not shake due to the external vibration.

(1) How to Handle the Package

� Do not hit or drop the package. No special treatment is conducted on this package to endure a

drop or impact on it.

� Do not attempt to carry a heavy package with only one worker. Also, have an appropriate

method for transportation.

� When hanging up with ropes, support on the reinforcement frame on the bottom of the lumber

base. When bringing up the package with a forklift, also support on the bottom of the lumber base.

� Handle with care when putting the package down to avoid impact or bounce. � Do not step on the package. � Do not put anything on the package that could deform or damage it.

(2) How to Handle after Unpackaged

� Fix the slider so they would not accidently move during transportation. � If the tip of an actuator is overhanging, have an appropriate way to fix it to avoid shaking due to

the external vibration. In the transportation without the tip being fixed, do not apply any impact with 0.3G or more.

� When hanging up with ropes, have appropriate cushioning to avoid any deformation of the

actuator body. Also keep it in stable horizontal orientation. Make a fixture utilizing the attachment holes and the tapped holes on the actuator body if necessary.

� Do not attempt to apply load on the actuators or the connector box. Also pay attention not to

pinch cables and bend or deform them forcefully.

[3] Handling in Condition of being assembled in Machinery Equipment (System)

These are some caution notes for when transporting the actuator being assembled in the machinery equipment (system):

� Fix the slider so they it would not move during transportation. � If the tip of an actuator is overhanging, have an appropriate way to fix it to avoid shaking due to

the external vibration. In the transportation without the tip being fixed, do not apply any impact with 0.3G or more.

� When hanging up the machinery equipment (system) with ropes, do not attempt to apply load on

the actuators or the connector box. Also pay attention not to pinch cables and bend or deform them forcefully.

2. Installation

2.2 Installation and Storage • Preservation Environment

[1] Installation Environment

The actuator should be installed in a location other than those specified below. In general, the installation environment should be one in which an operator can work without protective gear. Also provide sufficient work space required for maintenance inspection.

� Where the actuator receives radiant heat from strong heat sources such as heat treatment

furnaces

� Where the ambient temperature exceeds the range of 0 to 40�C � Where the temperature changes rapidly and condensation occurs � Where the relative humidity exceeds 85% RH � This actuator possesses the water durability of IP67 protection structure. � Where the actuator receives direct sunlight � Where the actuator is exposed to corrosive or combustible gases � Where the ambient air contains a large amount of powder dust, salt or iron (at level exceeding

what is normally expected in an assembly plant)

� Where the actuator is subject to splashed oil (including oil mist or cutting fluid) or chemical

solutions

� Where the actuator receives impact or vibration

If the actuator is used in any of the following locations, provide sufficient shielding measures:

� Where noise generates due to static electricity, etc. � Where the actuator is subject to a strong electric or magnetic field � Where the actuator is subject to ultraviolet ray or radiation

[2] Storage  Preservation Environment

� The storage and preservation environment should comply with the same standards as those for

the installation environment. In particular, when the machine is to be stored for a long time, pay close attention to environmental conditions so that no dew condensation forms.

� Unless specially specified, moisture absorbency protection is not included in the package when

the machine is delivered. In the case that the machine is to be stored and preserved in an environment where dew condensation is anticipated, take the condensation preventive measures from outside of the entire package, or directly after opening the package.

� For storage and preservation temperature, the machine withstands temperatures up to 60�C for

a short time, but in the case of the storage and preservation period of 1 month or more, control the temperature to 50�C or less.

� Storage and preservation should be performed in the horizontal condition. In the case it is stored

in the packaged condition, follow the posture instruction if any displayed on the package.



2.3 How to Install

This chapter explains how to install the actuator on your mechanical system.

2.3.1 General Rules on Installation

Follow the information below when installing the actuator, as a rule. Do pay attention to these items (except with custom-order models).

� : Possible � : Not possible

Horizontal

installation

Vertical

installation

Sideway

installation

Ceiling Mount

installation

�

× ×

�

Installation Orientation

Horizontal Vertical Sideway Ceiling Mount

The figures above are motor on top side.

Caution: In the Ceiling mount installation, the belt cover may bend, and it will be likely to

interfere with the work part. When the stroke is more than 500mm for BA6 or BA6U, or the stroke more than 600mm for BA7 or BA7U, make a gap to the slider seat to attach a work part.

Type Stroke Distance A BA6, BA6U 500mm to 1000mm 5mm or more BA7, BA7U 600mm to 1200mm 5mm or more

2. Installation

2.3.2 Installing the Main Body

The actuator base has mounting holes. Affix the actuator with M4 hexagon socket-head bolts using these holes. Use of high strength bolts of ISO-10.9 or higher is recommended.

The length of mounting bolts varies depending on the material of the machine frame.

• Steel frame: M4 × 10

• Aluminum frame: M4 × 15

Reamed positioning pin holes are provided in the back face of the base. Use these holes as necessary.

• Reamed hole: �4H7, depth 5mm or less

[Base seating surface] The base seating surface was changed and the width was reduced in order to minimize base deformation caused by the installation surface shape when fixing the actuator with bolts (from August

2010). The installation dimensions stay the same.

�

Base seating

surface

Before change

After change

0.1mm

BA6=7.5mm BA7=6.5mm

�

Tightening torque: 2.3N•m (0.23kgf•m

)

2.3.3 Mounting Surface

• For the platform to install the actuator on, ensure the structure has enough stiffness to avoid vibration being generated.

• The surface where the actuator will be mounted should be machined or be equally level and the flatness tolerance between the actuator and the table should be within 0.05mm/m.

• Provide enough space around the actuator to permit maintenance work to be done.

• The slider traveling plane is the reference plane for the actuator base and the lower surface.

• When traveling precision is required, use this as the datum surface for mounting.

Datum surface

Caution: As shown above, the side faces of the base provide the datum surfaces for slider

travel. When precision is required, use these surfaces as the datum surfaces for mounting.

When using the base as the datum planes for mounting the actuator to the machine frame, follow the machining dimensions shown below.

R0.3 or less

2 to 3.5

2. Installation

2.3.4 Installing the Load to the Slider

 There are tapped holes on the top surface of the slider. Affix the work part (transported object) here.  There are two reamed holes on the top surface of the slider. Use these reamed holes if repeatability

of attaching and detaching is required. Also, if small tuning such as perpendicularity is required, use one of the reamed holes for the tuning.

 Refer to the following table for the screwed depth and reamed depth. Screwing further than indicated

in the table may destroy the tapped hole or lower the reinforcement of the attachment of the work part, result in the drop of the accuracy or an unexpected accident.

Sizes and depths of tapped holes and reamed holes on slider

Model

Tapped hole

diameter

Tapping

depth

A B C

Reamed

hole

Reamed

depth

BA6/BA6U M5 10mm 50mm 32mm 31mm

5H7

10mm

BA7/BA7U M5 10mm 65mm 47mm 40mm

5H7

10mm

The tightening torque is follows.

• When the bolt-bearing surface is steel: 7.5N·m (0.77kgf·m)

• When the bolt-bearing surface is aluminum: 4.3N·m (0.44kgf·m)

Reamed hole

Tightening screws

• Use hexagonal socket head bolts for the male threads for installing the base.

• Use of high–tension bolts meeting at least ISO 10.9 is recommended.

• For the effective engagement length between the bolt and female thread, provide at least the applicable value specified below: Female thread is made of steel material � Same length as the nominal diameter Female thread is made of aluminum � 2 times of nominal diameter

Caution: Pay attention when selecting the screw length. Use of a screw with inappropriate

length may destroy a tapped hole or cause a lack in the attachment strength of the transported object, which may result in a cause of an unexpected accident.

3. Connecting with the Controller

For the connection of an actuator to the controller, apply an IAI dedicated controller and dedicated connection cable.

• If the dedicated connection cable cannot be secured, reduce the load on the cable by allowing it to deflect only by the weight of the cable or wire it in a self–standing cable hose, etc., having a large radius.

• Do not cut and reconnect the dedicated connection cable for extension or shorten the cable.

• Do not pull on the dedicated connection cable or bend it forcibly.

• The actuator cable coming out of the motor unit is not meant to be bent. Fix the cable so it would not be bent repeatedly.

Please consult with IAI if you require a different kind of cable than the one supplied.

[Connecting with the PCON, RPCON and PSEL Controller]

Dedicated cables

� Motor cable (Robot cable) CB-RCP2-MA�� Encoder cable CB-RCP2-PB��/ Robot encoder cable CB-RCP2-PB��-RB

�� indicates the cable length. A desired length up to 20m can be specified. Example) 080 = 8m

Dedicated Connection Cable (Connect RCP2 with the dedicated controller)

Dedicated Controller

Robot Cable r = 54mm or more (Movable Use) Standard Cable r = 75mm or more (Fixed Use)

3. Connecting with the Controller

[Connecting with the PMEC, PSEP and MSEP Controller]

� � �

Dedicated cables � Motor • Encoder Integrated Cables CB-PSEP-MPA�� indicates the cable length. A desired length up to 10m can be specified. Example) 080 = 8m

Dedicated Connection Cable (Connect RCP2 with the dedicated controller)

Dedicated Controller

Robot Cable r = 84mm or more (Movable Use) Standard Cable r = 42mm or more (Fixed Use)

Warning: For wiring, please follow the warnings stated below. When constructing a

system as the machinery equipment, pay attention to the wiring and connection of each cable so they are conducted properly. Not following them may cause not only a malfunction such as cable breakage or connection failure, or an operation error, but also electric shock or electric leakage, or may even cause a fire.

• Use dedicated cables of IAI indicated in this operating manual. Contact us if you wish to have a change to the specifications of the dedicated cables.

• Make sure to turn the power off in the process of power line or cable connection or disconnection.

• Do not attempt to cut a dedicated cable with connectors on both ends to extend, shorten or re-joint it.

• Hold the dedicated cable to avoid mechanical force being applied to the terminals and connectors.

• Use a cable pipe or duct to have an appropriate protection when there is a possibility of mechanical damage on a dedicated cable.

• In case a dedicated cable is to be used at a moving part, make sure to lay out the cable without applying any force to pull the connector or extreme bend on the cable. Do not attempt to use the cable with a bending radius below the allowable value.

• Make certain that the connectors are plugged properly. Insufficient connection may cause an operation error, thus it is extremely risky.

• Do not lay out the cables to where the machine runs over them.

• Pay attention to the cable layout so it will not hit peripherals during an operation. In case it does, have an appropriate protection such as a cable track.

• When a cable is used hanging on the ceiling, presenting an environment that the cable swings with acceleration or wind velocity.

• Make sure there is not too much friction inside the cable storage equipment.

• Do not apply radiated heat to power line or cables.

• Have a sufficient radius for bending, and avoid a bend concentrating on one point.

Steel Strap (Piano Wire)

Tie them up softly.

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

3. Connecting with the Controller

• Do not pull the cable with a strong force.

• Pay attention not to concentrate the twisting force to one point on a cable.

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

• When a cable is fastened to affix, make sure to have an appropriate force and do not tighten too much.

Do not use spiral tube in any position where cables are bent frequently.

• PIO line, communication line, power and driving lines are to be put separately from each other and do not tie them together. Arrange so that such lines are independently routed in the duct.

Power Line

Duct

I/O Line (Flat Cable, etc.)

Follow the instructions below when using a cable track.

• If there is an indication to the cable for the space factor in a cable track, refer to the wiring instruction given by the supplier when storing the cable in the cable track.

• Avoid getting cables twined or twisted in the cable track, and also having the cables move freely and do not tie them up. (Avoid tension being applied when the cables are bent.) Do not pile up cables. It may cause faster abrasion of the sheaths or cable breakage.

3. Connecting with the Controller

4. Maintenance Inspection

4.1 Inspection Items and Schedule

Follow the maintenance inspection schedule below. It is assumed that the equipment is operating 8 hours per day. If the equipment is running continuously night and day or otherwise running at a high operating rate, inspect more often as needed.

External visual inspection Check interior Greasing

Belt loosening

Start of work inspection

�

1 month inspection

�

6 month inspection

� �

12 month inspection

�

� � �

Every 6 months thereafter

�

Every 12 months thereafter

� � � �

* If the actuator are operated back and forth repeatedly over a distance of 30mm or less, the oil film

created by the grease may be broken. As a guide, move the actuators back and forth repeatedly for around 5 cycles over a distance of 50mm or more after every 5,000 to 10,000 cycles. A layer of the grease will recover.

4.2 External Visual Inspection

An external visual inspection should check the following things.

�

Main unit Loose actuator mounting bolts, other loose items Cables Scratches, proper connections Overall Irregular noise, vibration

�

4.3 Cleaning

• Clean the exterior as needed.

• Wipe off dirt with a soft cloth.

• Do not use strong compressed air on the actuator as this may force dust into the crevices.

• Do not use petroleum-based solvent on plastic parts or painted surfaces.

• If the unit is badly soiled, apply a neutral detergent or alcohol to a soft cloth, and wipe gently.

4.4 Interior Inspection

After turning off the power, remove the side covers and belt cover to conduct visual checks. Check the following items during interior inspection.

Main unit Loose mounting bolts Guides Lubrication appropriate Soiling Drive belt Scratches Loose Backside of belt cover Lubrication appropriate

The side covers and belt cover can be removed using a hex wrench of 2mm across flats.

Make a visual check of the interior to see if there is any dust or foreign matter in the unit and also check the lubrication condition. Even if the grease you see around the parts is brown, the lubrication is fine as long as the traveling surface appears shiny. If the grease becomes dirty and dull or if the grease has worn away due to extended operating time, lubricate the parts after cleaning them. For details on how to check the drive belt, refer to the check items listed in 4.7.

• Checking the lubrication of the backside of the belt cover Check the lubrication condition of the backside of the belt cover and the belt-cover support (made of resin) at the center of the slider to make sure the frictional resistance between the slider and belt cover is minimized and the slider can move smoothly. If lubrication is not enough, apply the following grease.

Kyodo Yushi Multemp LRL3 or equivalent

revoc tleb fo ediskcaB troppus revoc-tleB

4. Maintenance Inspection

4.5 Internal Cleaning

• Wipe off dirt with a soft cloth.

• Do not use strong compressed air on the actuator as this may force dust into the crevices.

• Do not use petroleum-based solvent, neutral detergent or alcohol on the belt.

Caution: Do not use flushing oil, molybdenum grease or anti-rust lubricant.

When grease is soiled with large amounts of foreign substances, wipe off the dirty grease and then apply new grease.

4.6 Grease Supply to the Guides

4.6.1 Grease to Apply

Lithium grease No. 2 is used on the guides. The following grease is applied when we ship the unit.

Idemitsu Kosan Daphne Eponex Grease No.2

Other companies also sell a grease similar to this. If ordering from another maker, give the name of this product and request something comparable.

4.6.2 How to Apply the Grease

1) Remove the side covers on both sides.

2) When greasing the guide, use a spatula or grease applicator to squeeze or inject grease into the space between the slider and base, and then move the slider back and forth several times to let the grease spread evenly. Remove excess grease.

3) Follow the same steps to apply grease on the other guide

4) Install the side covers.

Warning: Do not attempt to apply fluorine and lithium grease. When mixed with lithium

grease, not only decrease the grease characteristics, but also may damage the actuator.

Caution: In case the grease got into your eye, immediately go to see the doctor to get an

appropriate care. After finishing the grease supply work, wash your hands carefully with water and soap to rinse the grease off.

4. Maintenance Inspection

4.7 Drive Belt

4.7.1 Inspecting the Belt

Remove the side covers and visually inspect the belt. Durability of the drive belt is affected significantly by the operating condition, and there is no standard guideline as to when the belt should be replaced. Generally, the belt is designed to withstand several million cycles of flexing loads. As a practical guideline, replace the drive belt when any of the conditions listed below is observed:

• The teeth and end faces of the belt have worn significantly.

• The belt has swollen due to deposits of oil, etc.

• Cracks and other damages are found on the teeth or back of the belt.

• The belt has broken.

4.7.2 Applicable Belt

Manufacturer Model Number Material

Mitsuboshi Belting Long Belt OTG100S3M, 10mm wide Urethane specification

4.7.3 Checking and Adjusting the Belt Tension

[1] Checking the Tension

As a guideline, belt tension is evaluated by the load needed to deflect the belt by 10mm when the belt is pushed near the stroke center. The table below lists the appropriate loads needed to achieve a 10mm deflection on each belt used at different strokes. If the measured load is less than the applicable value by approx. 20% or more, the belt is loose and its tension must be adjusted. Appropriate loads to achieve 10mm deflection

Model

Top: Stroke (mm) Bottom: Load (kgf)

500 550 600 650 700 750 800 850 900 950 1000 - - BA6

BA6U

0.32 0.31 0.31 0.30 0.35 0.35 0.34 0.34 0.40 0.40 0.39 - 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200BA7

BA7U

0.37 0.36 0.35 0.35 0.41 0.40 0.40 0.39 0.39 0.45 0.45 0.44 0.44

Front stroke end: Pulley center

Stroke center

Motor-side stroke end: 45mm forward of end face

Move the slider to the motorside mechanical end.

Deflection: 10mm

F: Load

45mm

4. Maintenance Inspection

[2] Adjusting the Tension

Adjust the tension using the affixing bolts in the pulley bracket on the counter-motor side.

1) Move the slider to the motor-side mechanical end.

2) Loosen the affixing bolts (using a hex wrench of 3mm across flats).

3) Guide a wire around the bracket and pull the wire uniformly from both ends using tension gauges.

4) With the wire pulled to a specified tension from both ends, tighten the affixing bolts carefully by making sure the bracket does not deform. The appropriate tension varies depending on the stroke.

Model Tension

Stroke: 500 to 600mm Stroke: 700 to 850mm Stroke: 900 to 1000mmBA6

BA6U

6Kgf 8Kgf 10Kgf

Stroke: 600 to 750mm Stroke: 800 to 950mm Stroke: 1000 to 1200mmBA7

BA7U

8Kgf 10Kgf 12Kgf

Wire

Pull both ends uniformly using tension gauges by making sure the pulley bracket does not deform.

M4 hexagon socket-head bolts for adjustment Tightening torque: 360N

cm (36.7kgf cm)

(Note) The user must provide an appropriate wire available on the market.

4.7.4 Replacing the Belt

[Items Required for Replacement]

• Replacement drive belt

• Tension adjustment wire (provide a commercially available wire like the one shown in the photograph at right)

• Phillips screwdriver set and hex wrench set

• Tension gauge (capable of applying a tensile load of 12kgf or more)

• Grease (Kyodo Yushi’s Multemp LRL3 or equivalent)

[Procedure]

1) Remove the load from the slider.

2) Remove the belt cover and one of the side covers (using a hex wrench of 2mm across flats).

[Counter-motor side] [Motor side]

Remove the belt-cover affixing screws.

Remove the side-cover affixing screws.

3) Remove the belt-cover support (resin) (using a hex wrench of 2.5mm across flats). Wipe off grease attached on the support.

4) Remove the belt-holder affixing bolts. (using a hex wrench of 2.5mm across flats).

4. Maintenance Inspection

5) Loosen the tension adjustment bolts (using a hex wrench of 3mm across flats). If the bolts are not readily accessible, remove the other side cover.

6) Move the slider to expose the belt holder.

Belt holder

7) Separate the belt and pull it out of the actuator.

• Remove the belt-affixing bolts (using a hex wrench of 2.5mm across flats) .

• Removed belt • Actuator without belt

8) Remove the rear cover (using a hex wrench of 2.5mm across flats).

9) Remove the front-cover affixing bracket (using a hex wrench of 2.5mm across flats).

10) Install a new belt by guiding it around the pulleys.

• Insert the belt from the spaces provided on both sides of the motor side pulley.

• Guide the belt through the slider.

• Guide the belt around the counter motor side pulley (front side).

4. Maintenance Inspection

11) Affix the belt to the belt holder. Align the belt teeth on the belt holder with the drive belt, and tighten the bolts (M3 × 6).

Tightening torque: 154N cm (15.7kgf cm)

12) Move the slider to a position where it aligns with the mounting holes in the belt holder, and tighten the bolts (BA6: M3 × 6 / BA7: M3 × 12).

Tightening torque: 83N cm (8.5kgf cm)

13) Affix the belt-cover support (resin) using the bolts (M3 × 6).

14) Adjust the belt to the specified tension. Move the slider to the motor-side mechanical end, guide a wire around the counter-motor side pulley bracket, and then pull the wire uniformly from both ends using tension gauges. With the wire pulled to a specified tension from both ends, tighten the adjustment bolts. (Refer to the table below to find the tension appropriate for your actuator and the stroke.)

Model Tension

Stroke: 500 to 650mm Stroke: 700 to 850mm Stroke: 900 to 1000mm BA6

BA6U

6Kgf 8Kgf 10Kgf

Stroke: 600 to 750mm Stroke: 800 to 950mm Stroke: 1000 to 1200mmBA7

BA7U

8Kgf 10Kgf 12Kgf

Wire

Pull both ends uniformly using tension gauges by making sure the pulley bracket does not deform.

M4 hexagon socket-head bolts for adjustment Tightening torque: 360N

cm (36.7kgf cm)

15) Apply grease on the belt-cover support and the backside of the belt cover.

Kyodo Yushi Multemp LRL3 or equivalent

[Belt-cover support] [Back of belt cover]

16) Install the side cover (thin-head screw M4 × 6, 2pcs), front cover (hexagon socket-head bolt M3 × 8, 2pcs) and rear cover (hexagon socket-head bolt M3 × 8, 2pcs). If the motor is installed at the bottom of the actuator, also install the bracket cover (thin-head screw M3 × 4, 2pcs).

4. Maintenance Inspection

17) Install the belt cover (thin-head screw M4 × 6, 2pcs). Move the slider back and forth over the entire stroke to make sure it does not contact the belt cover.

Check if the clearance is sufficient.

4.8 Replacing the Motor

4.8.1 BA6/BA7 (Motor on the Top)

[Items Required for Replacement]

• Replacement motor (with the motor shaft preassembled with a pulley assembly: see photograph 1))

• Tension adjustment wire (provide a commercially available wire like the one shown in photograph 2))

• Phillips screwdriver set and hex wrench set

• Tension gauge (capable of applying a tensile load of 12kgf or more)

• Grease (Kyodo Yushi’s Multemp LRL3 or equivalent)

[Photograph 1)] [Photograph 2)]

Pulley assembly

[Procedure]

1) First, remove the drive belt. Remove the load from the slider and follow steps 1) to 7) in 4.7.4, “Replacing the Belt,” to remove the belt.

2) Remove the rear cover (using a hex wrench of 2.5mm across flats).

4. Maintenance Inspection

Caution: When applying the force, do not

touch the encoder directly.

3) Loosen the four pan-head screws affixing the motor cap, and pull out the motor cap.

4) Remove the two pan-head screws affixing the cable-mounting plate, and separate the plate from the motor cover.

5) Pull out the encoder connector.

6) Pull out the motor connector.

7) Remove the other side cover.

8) Remove the motor bracket.

• Remove the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats.

[Rear cover side] [Slider side]

• Pull out the motor bracket by hand.

Caution: A parallel pin is pressed into

the base. If the motor bracket does not come off easily, slowly turn the motor bracket by hand and pull it out.

Parallel pin

9) Remove the motor from the motor bracket.

• Remove the affixing bolts (M3 × 28, 4pcs)

using a hex wrench of 2.5mm across flats.

• After the motor has been removed

10) Install a new motor to the motor bracket. When installing the motor, be careful not to damage the bearing at the end of the motor shaft.

Tightening torque: 90 N cm (9.2 kgf cm)

4. Maintenance Inspection

11) Affix the motor bracket on the base. Tighten the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats.

Tightening torque: 176N cm (18kgf cm)

Securely tighten the bolts with the slider firmly pressed against the motor bracket.

12) Plug in the motor connector. 13) Plug in the encoder connector..

Caution: When applying the force,

directly.

do not touch the encoder

14) Store the cables into the motor cover and affix the cable-mounting plate using the pan-head screws (M2.6 × 5, 2pcs).

15) Tighten the motor cap and motor cover together using the pan-head screws (4pcs). Applicable screws (BA6: M3 × 80 / BA7: M3 × 90)

16) Install the drive belt, adjust it to the specified tension, and then install the covers. Follow steps 9) to

17) in 4.7.4, “Replacing the Belt”

4.8.2 BA6U/BA7U (Motor at the Bottom)

[Items Required for Replacement]

• Replacement motor (with the motor shaft preassembled with a joint hub: see photograph 1))

• Tension adjustment wire (provide a commercially available wire like the one shown in photograph 2))

• Setscrew (M4 × 5, flat-tip, precoated)

• Setscrew (M4 × 5, recessed-tip, precoated)

• 1.5mm thick spacer (or thickness gauge)

• Phillips screwdriver set and hex wrench set

• Tension gauge (capable of applying a tensile load of 12kgf or more)

• Grease (Kyodo Yushi’s Multemp LRL3 or equivalent)

• Hot gun (used if the setscrews do not come off)

[Photograph 1)] [Photograph 2)]

Joint hub

[Procedure]

1) First, remove the drive belt. Remove the load from the slider and follow steps 1) to 7) in 4.7.4, “Replacing the Belt,” to remove the belt.

2) Remove the bracket and rear cover.

Use a hex wrench of 1.5mm across flats.

Use a hex wrench of 2.5mm across flats.

4. Maintenance Inspection

3) Remove the motor bracket.

• Remove the affixing bolts (M4 × 45, 4pcs)

using a hex wrench of 3mm across flats.

• Pull out the motor bracket by hand.

4) Remove the two setscrews (M4 × 5, precoated) affixing the pulley assembly (using a hex wrench of 2mm across flats), and pull out the pulley assembly. If the setscrews do not come off, use a heat gun to heat the adhesive attached at the screw ends.

Caution: Remove the set screw carefully so as not to misplace the set pieces.

Set screw (M4 x 5, recessed-tip, precoated) and set piece (opposite side of the joint hub’s D-cut face)

Set screw (M4 x 5, flat-tip, precoated) (joint hub’s D-cut face)

5) Remove the four pan-head screws affixing the motor cap and two pan-head screws affixing the cable-mounting plate, and separate the motor cap and cable-mounting plate from the motor cover.

6) Pull out the motor connector. 7) Pull out the encoder connector.

Caution: When applying the force,

do not touch the encoder directly.

8) Remove the motor.

• Remove the affixing bolts (M3 × 8, 4pcs)

using a hex wrench of 2.5mm across flats.

• Pull out the motor downward by slightly tilting it to right and left.

• After the motor has been removed • Pull out the bearing by hand.

4. Maintenance Inspection

9) Install a new motor on the base and insert the bearing.

• Tighten the affixing bolts (M3 × 8, 4pcs) using a hex wrench of 2.5mm across flats.

• Insert the bearing by hand.

Tightening torque: 90N cm (9.2kgf cm)

10) Plug in the encoder connector. 11) Plug in the motor connector.

Caution: When applying the force,

do not touch the encoder directly.

12) Store the cables into the motor cover and affix the cable-mounting plate using the pan-head screws (M2.6 × 5, 2pcs).

13) Tighten the motor cap and motor cover together using the pan-head screws (4pcs). Applicable screws (BA6U: M3 × 73 / BA7U: M3 × 85)

14) Affix the pulley assembly to the joint hub.

• Provide a 1.5mm clearance between the joint hub and pulley assembly.

Example: Thickness gauge

1.5mm

• Tighten it with new setscrews at two points with using a 2mm hex wrench.

D-cut face

Opposite side of

D-cut face

Set piece

Setscrew (M4 x 5, flat-tip, precoated)

Setscrew (M4 x 5, recessed-tip, precoated)

Caution: Always use new setscrews with a new motor.

4. Maintenance Inspection

Tightening torque: 176N cm (18kgf cm)

Securely tighten the bolts with the slider firmly pressed against the motor bracket.

15) Install the motor bracket.

• Align the motor bracket with the pilot section of the bearing and insert the bracket carefully so as not to damage the outer periphery of the bearing.

• Tighten the affixing bolts (M4 × 45, 4pcs) using a hex wrench of 3mm across flats.

16) Install the drive belt, adjust it to the specified tension, and then install the covers. Follow steps 9) to

17) in 4.7.4, “Replacing the Belt.”

4. Maintenance Inspection

5. External Dimensions

5.1 RCP2-BA6/BA6U

± 0.02

55 50

± 0.02

(240)

10 71.5 10.56523

Secure at least 100

60Stroke

4.7 4.7

8238

5485

118.5

63.555

73 53

2-φ 5H7 reamed, depth 10

4-M5 depth 10

(Motor on top type : BA6)

(Motor on bottom type : BA6U)

Cable joint connector

MEHOMESEME

A area

75.5

φ 8

1.5

Datum surface

φ 4.5

4.54

4.5

Detail : A (attachment hole and datum surface)

Datum point for Ma moments offset

P (reamed hole and slotted hole)

Oblong hole, depth 5.5 from base bottom

2-φ 4H7 reamed, depth 5.5 from base bottom

(from opposite side) (from opposite side)

S-4.5 drilled hole, φ8 counterbore depth 4.5

55 B 80

N × 100

+0.012

Detail : Oblong hole

ME : Mechanical End SE : Stroke End

Stroke 500 550 600 650 700 750 800 850 900 950 1000

L 740 790 840 890 940 990 1040 1090 1140 1190 1240 A 720 770 820 870 920 970 1020 1070 1120 1170 1220 B 85 35 85 35 85 35 85 35 85 35 8.5 N 5 6 6 7 7 8 8 9 9 10 10 P 570 620 670 720 770 820 870 920 970 1020 1070 S 14 16 16 18 18 20 20 22 22 24 24

Weight [kg] 2.8 2.9 3.0 3.2 3.3 3.4 3.5 3.7 3.8 3.9 4.1

5. External Dimensions

5.2 RCP2-BA7/BA7U

8328

55 65 947

± 0.02

10.56523

71.5

68.560

10 1048

128.5

4-M 5×10

75.5

(240)

4.7

SEME

4.7

83 58

4.5

φ 4.5

φ 8

2.5

± 0.02

80B55

+0.012

ME : Mechanical End SE : Stroke End

2-φ 5H7 reamed, depth 10

Secure at least 100

(Stroke)

(Motor on top type : BA7)

(Motor on bottom type : BA7U)

Cable joint connector

HOME

2-φ 4H7 reamed, depth 5.5 from base bottom

(from opposite side)

S-4.5 drilled hole, φ8 counterbore depth 4.5

A area

Datum point for Ma moments offset

Datum surface

Detail : A (attachment hole and datum surface)

P (reamed hole and slotted hole)

Oblong hole, depth 5.5 from base bottom

N × 100

Detail : Oblong hole

Stroke 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200

L 855 905 955 1005 1055 1105 1155 1205 1255 1305 1355 1405 1455 A 835 885 935 985 1035 1085 1135 1185 1235 1285 1335 1385 1435 B 100 50 100 50 100 50 100 50 100 50 100 50 100 N 6 7 7 8 8 9 9 10 10 11 11 12 12 P 685 735 785 835 885 935 985 1035 1085 1135 1185 1235 1285 S 16 18 18 20 20 22 22 24 24 26 26 28 28

Weight [kg] 3.6 3.7 3.9 4.0 4.2 4.3 4.4 4.6 4.7 4.9 5.0 5.2 5.3

5. External Dimensions

6. How to use the home mark

Please affix these marks to the actuator as home markers as needed.

Home mark sticker

Home mark scale × 4 Home mark × 4 (Scale: 1 mm graduation mark, 10 mm width)

• Peel off the marks from the base sheet. Note 1. Every mark has sticky back.

2. Remove smear and stain from the surface.

3. Avoid label or nameplate as a marking location.

Contents of sticker

× 1 sheet

Example of Use

1) Used to indicate the direction of actuator home

On the slider

On the base near home position

Motor

2) Used as stop positions

Motor

On the slider

At stop positions on the base

3) Used for position deviation check

On the base

On the slider

• Place the marks when the actuator is stopped at home position.

6. How to use the home mark

7. Life

The product life is assumed to be 5,000km (reference) under the condition that it runs with maximum load capacity and maximum acceleration/deceleration.

8. Warranty

8.1 Warranty Period

One of the following periods, whichever is shorter:

� 18 months after shipment from IAI � 12 months after delivery to the specified location � 2,500 hours of operation

8.2 Scope of the Warranty

Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized

dealer. (2) The breakdown or problem in question occurred during the warranty period. (3) The breakdown or problem in question occurred while the product was in use for an appropriate

purpose under the conditions and environment of use specified in the instruction manual and

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

quality issue with our product.

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

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

modification or repair)

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

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

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

8.3 Honoring the Warranty

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

8.4 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.

8. Warranty

8.5 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 instruction manual.

8.6 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

8. Warranty

Change History

Revision Date Description of Revision

June 2008

September 2010

April 2011

First edition

Second edition

Third edition

• Changed the logo at the top of page “IA” to “RC” for all pages.

• Danger, Operation Deleted “� If you are using a pace maker ... (snip) ... to malfunction.”

• Warning, Installation Deleted “Be sure to provide Class D grounding ... (snip) ... or malfunction.”

• Warning, Operation Deleted “� The cable supplied with the product... (snip) ... use robot cables.”

• Caution, Installation Changed “� Do not install the product in a place subject to large vibration or impact (4.9 m/s2 or more). Doing so may result in the manufacturing of the product.” to “Do not install it in a place subject to large vibration or impact.”

• Caution, Operation Deleted “ Do not bring a floppy disk... (snip) ... may destroy the data in the floppy disk, etc.”

• Deleted Note “General”

• Deleted Others “� If you have any question... (snip) ... at the end of this operation manual.” Prohibited Handling of Cables Deleted “The Rules for Handling Cables (Must be Observed!).” Prohibited Handling of Cables, 7. Notes on use of cable tracks Added “� The supplied cable is not a robot cable… (snip) ... in a cable track.” Added an explanation drawing. Deleted item 10 in Prohibited Handling of Cables

• Changed the content of the operating environment on page 6. “• The unit should not be subject to vibrations greater than 0.3G.” "• Impact and vibration must not be transmitted.”

• Added “A reamed positioning pin holes … (snip) ... as necessary. "Reamed hole: �4H7, depth 5 mm or less.” on page 7. Reamed hole in the table on page 9, two locations "�5H10” “�5H7”

• Added Warning, "Never use fluorine grease. ... (snip) ... damage the

machine.” on page 15.

• Added Contact address: IAI Customer Center Eight on the back cover.

Fourth edition

• Added “Precautions” at the top.

• Added change of base seating surface on page 7.

Fifth edition

• A page for CE Marking added

Change History

Revision Date Description of Revision

January 2012

March 2012

March 2013

Sixth edition

• Contents changed in 3. Warranty

• Relation of Speed and Maximum Load capacity added

Seventh edition

• CAUTION deleted

• Please Read Before Use added

• Contents added and changed in Safety Guide on pages 1 to 7

• Caution in Handling added in page 8

• Note added to describe availability of installation for each installation posture in page 16

• Warning notes added such as in case the grease got into your eye, immediately go to see the doctor for an appropriate care in page 26

• External Dimensions added in pages 47 and 48

Eighth edition

• Revised overall

Change History

Manual No.: ME3633-8A (March 2013)

13.03.000

Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan

TEL +81-54-364-5105 FAX +81-54-364-2589

website: www.iai-robot.co.jp/

Ober der Röth 4, D-65824 Schwalbach am Taunus, Germany

TEL 06196-88950 FAX 06196-889524

SHANGHAI JIAHUA BUSINESS CENTER A8-303, 808, Hongqiao Rd. Shanghai 200030, China

TEL 021-6448-4753 FAX 021-6448-3992

website: www.iai-robot.com

Technical Support available in USA, Europe and China

Head Office: 2690 W. 237th Street, Torrance, CA 90505

TEL (310) 891-6015 FAX (310) 891-0815

Chicago Office: 1261 Hamilton Parkway, Itasca, IL 60143

TEL (630) 467-9900 FAX (630) 467-9912

TEL (678) 354-9470 FAX (678) 354-9471

website: www.intelligentactuator.com

Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066

IAI America RCP2-BA7U User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

Table of Contents

Safety Guide

Caution in Handling

International Standards Compliances

Names of the Parts

1. Specifications Check

1.1 Checking the Product

1.2 Specification

1.3 Options

1.4 Motor • Encoder Cables

2. Installation

2.1 Transportation

2.2 Installation and Storage • Preservation Environment

2.3 How to Install

3. Connecting with the Controller

4. Maintenance Inspection

4.1 Inspection Items and Schedule

4.2 External Visual Inspection

4.3 Cleaning

4.4 Interior Inspection

4.5 Internal Cleaning

4.6 Grease Supply to the Guides

4.7 Drive Belt

4.8 Replacing the Motor

5.1 RCP2-BA6/BA6U

5. External Dimensions

5.2 RCP2-BA7/BA7U

6. How to use the home mark

7. Life

8. Warranty

8.1 Warranty Period

8.2 Scope of the Warranty

8.3 Honoring the Warranty

8.4 Limited Liability

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

8.6 Other Items Excluded from Warranty

Change History