IAI America RCP2-CF User Manual

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RCP2 Series ROBO Cylinder Controller

Operation Manual Fifteenth Edition

Sixteenth Edition

Please Read Before Use

Thank you for purchasing our product. This Operation Manual explains the handling methods, structure and maintenance of this product, among others,

providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to

ensure safe use of the product. The CD 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. 24-V Power Supplies for Equipment Requiring a UL Certification

[1] The controller with the maximum current of 2 A (RCP2-C/CG) and 6 A (RCP2 -C F) are UL-certified.

However, a UL certification requires that the 24-V power supplies used with the controller conform to Class 2. If the user’s equipment must receive a UL certification, please use an input power supply and an I/O power supply both conforming to Class 2.

[2] RCP2 controller can be us ed in the environment of the pollution degree 2.

2. Basic Parameter Settings

After applying power, at least the three parameters specified below must be set in accordance with the specific application. Inappropriate For details on how to set the parameters, refer to “Parameter Settings” in the operation manual for the PC or teaching pendant.

[1] Selecting the PIO pattern

This controller provides six PIO (Parallel I/O) patterns to meet the needs of various applications. To select a desired PIO pattern, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern selection). The factory setting is “0.”settings of these parameters will prevent the controller from operating properly,

No. 25 setting

so exercise due caution.

Parameter

Conventional This pattern is compatible with the pin assignments of the RCP controller.

Standard All functions of the RCP controller are available, plus the home-return command input, servo ON input, reset input, moving output and ready output.

64-point positioning Compared with the standard pattern offering only 16 positioning points, this pattern provides up to 64 positioning points. However, the servo ON input, ready output and zone output have been removed.

2 zone output signals Compared with the standard pattern offering only one zone output signal, this pattern provides two zone output signals. However, the moving output has been removed. The boundaries for the second zone output signal are specified in parameter Nos. 23 and 24.

Teaching This pattern allows for normal positioning operation, as well as jogging and writing of current position to a specified position using I/Os. Switching between the normal positioning mode and teaching mode is effected by the MODE input signal. The mode switching completion output has been added to indicate that the modes have been switched. However, the zone output has been removed. (Note) Position data can be rewritten up to around 100,000 times.

4 points (air cylinder) Use of the RCP2 as an air cylinder is assumed in this pattern. The number of positioning points is limited to four, but a direct command input and a position complete output are provided for each target position in line with the conventional practi ce of air cylinder control. This lets the user control the RCP2 just like an air cylinder.

Feature of PIO pattern

[2] Enabling/disabling the servo ON input signal (SON)

The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side. Depending on the needs, therefore, the user must enable/disable this signal.

To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection).

Enable (use) the signal 0 Disable (do not use) the signal 1

If “0” or “2” has been selected as the above PIO pattern, the servo ON signal is not provided. However, you must still set “1: [Disable]” in parameter No. 21 (SON). (If “0” is set, the servo will not turn ON.) The factory setting for this parameter is “1: [Disable].”

[3] Enabling/disabling the pause signal (*STP)

The pause signal uses the contact B logic to provide a failsafe function. Therefore, this signal must remain ON in normal conditions of use. (The pause signal must also remain ON when issuing movement commands from the teaching pendant or PC.) Since there are applications where this signal is not used, a parameter is provided to disable the pause signal so it doesn’t have to be turned ON. To select a desired setting, set “0” or “1” in parameter No. 15 (Pause input disable selection).

Enable (use) the signal 0 Disable (do not use) the signal 1

If the pause input is not used, set “1: [Disable]” in this parameter and the signal need not be turned ON. The factory setting for this parameter is “0: [Enable].”

3. Recommendation for Backing up Latest Data

This controller 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 in the event of power failure, or 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] Hand write the position table and parameter table on paper.

4. Compatibility of Teaching Pendant

The existing teaching pendants of <RCA-T> and <RCA-E> types can be used with the RCP2 controlle r, but your RCA-T/RCA-E teaching pendant will require some modification. If you are using a teaching pendant of either type, please send it to IAI. We will perform the necessary modification and return it to you as soon as possible. Teaching pendants that have already been modified have a specific code at the end of their serial number. Please check the serial number of your teaching pendant to see if it requires modification.

Teaching pendant model number Code at the end of serial number

RCA-T …F3 (or later) RCA-E …H3 (or later) RCA-P …H3 (or later) RCB-J …B2 (or later)

5. PC Software Versions

The software versions that support this controller are 4.0.0.0 and later.

CE Marking

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

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

1. Overview..............................................................................................1

1.1 Introduction..................................................................................................................................... 1

1.2 How to Read Model Number..........................................................................................................2

1.3 Handling of Secondary Batteries for the Absolute Specification.................................................... 3

1.4 Safety Precautions.........................................................................................................................4

1.5 Warranty Period and Scope of Warranty........................................................................................5

2. Specifications.......................................................................................6

2.1 Basic Specifications........................................................................................................................6

2.1.1 Backup Batteries for the Absolute Specification...................................................................... 7

2.1.2 Specifications of the Large-Capacity Type (RCP2-CF)...........................................................8

2.2 Name and Function of Each Part of the Controller........................................................................9

2.2.1 Names.....................................................................................................................................9

2.2.2 Functions.................................................................................................................................9

2.3 External Dimensions .................................................................................................................... 11

2.3.1 Standard Specification........................................................................................................... 11

2.3.2 Absolute Specification with Battery Bracket..........................................................................12

Absolute Specification without Battery Bracket ..............................................................................13

2.3.3 Large-Capacity Type (RCP2-CF-***)..................................................................................... 14

3. Installation and Noise Elimination......................................................15

3.1 Installation Environment...............................................................................................................15

3.2 Power Supply...............................................................................................................................15

3.3 Noise Elimination and Grounding.................................................................................................15

3.4 Heat Radiation and Installation....................................................................................................17

4. Wiring.................................................................................................18

4.1 Internal Drive-Power Cutoff Relay T ype (RCP2-C, RCP2-CF).................................................... 18

4.1.1 Configuration.........................................................................................................................18

4.1.2 External Connection Diagram ...............................................................................................19

4.1.3 Wiring the Power Supply/Emergency-Stop Switch ...............................................................20

4.2 External Drive-Power Cutoff Relay Type (RCP2-CG)..................................................................27

4.2.1 Configuration.........................................................................................................................27

4.2.2 External Connection Diagram ...............................................................................................28

4.2.3 Wiring the Power Supply/Motor Power Cutoff Relay.............................................................29

4.3 Connecting the I/O Cables........................................................................................................... 32

 PIO pattern 0 [Conventional].................................................................................................32

 PIO pattern 1 [Standard]........................................................................................................33

 PIO pattern 2 [64-point positioning]....................................................................................... 34

 PIO pattern 3 [2 zone output signals]....................................................................................35

 PIO pattern 4 [Teaching]........................................................................................................36

 PIO pattern 5 [4 points] (air cylinder).....................................................................................37

4.4 Connecting the Actuator...............................................................................................................38

4.4.1 Motor Extension Cable.......................................................................................................... 38

4.4.2 Encoder Extension Cable......................................................................................................39

 [Standard controller (2 A)]......................................................................................................39

 [Large-capacity controller (6 A)]............................................................................................41

4.5 Connecting the Communication Cable.........................................................................................42

5. I/O Signal Control and Signal Functions............................................43

5.1 PIO Patterns and Signal Assignments......................................................................................... 43

5.1.1 Explanation of Signal Names................................................................................................44

 PIO pattern = “0: [Conventional],” “1: [Standard],” “2: [64-point positioning],” “3: [2 zone output

signals]”.................................................................................................................................44

 PIO pattern = “4: [Teaching]”.................................................................................................45

 PIO pattern = “5: [4 points].................................................................................................... 46

5.1.2 Signal Assignment T able for Respective PIO Patterns.........................................................47

5.2 Interface Circuit............................................................................................................................48

5.2.1 External Input Specifications.................................................................................................48

5.2.2 External Output Specifications..............................................................................................49

5.3 Details of I/O Signal Functions.....................................................................................................50

5.3.1. Details of Each Input Signal............................................................................................50

 Start (CSTR).......................................................................................................................... 50

 Command position number (PC1 to PC32)...........................................................................50

 Pause (*STP)........................................................................................................................50

 Home return (HOME)............................................................................................................51

 Servo ON (SON) ................................................................................................................... 51

 Alarm reset (RES)................................................................................................................. 51

 Operation mode (MODE) ......................................................................................................51

 Current-position write (PWRT)..............................................................................................52

 Jog (JOG+, JOG-).................................................................................................................52

 Movement to each position (ST0 to ST3)..............................................................................52

5.3.2 Details of Each Output Signal...............................................................................................53

 Completed position numb er (PM1 to P M32)......................................................................... 53

 Moving (M OVE).....................................................................................................................53

 Position complete (PEND).....................................................................................................53

 Home return completion (HEND).......................................................................................... 53

 Zone (ZONE1, ZONE2).........................................................................................................54

 Current operation mode (MODES)........................................................................................54

 Write completion (WEND).....................................................................................................54

 Completion of each position (PE0 to PE3)............................................................................54

 Ready (SRDY).......................................................................................................................55

 Alarm (*ALM)......................................................................................................................... 55

 Emergency stop (*EMGS).....................................................................................................55

(Reference) Output Signal Changes in Each Mode..................................................................... 55

6. Data Entry <Basics>..........................................................................56

6.1 Description of Position-Data Table...............................................................................................57

6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value.................................... 60

(1) SA5/SA6/SS type (2) SA7 type............................................................................................. 60

(3) SM type .................................................................................................................................61

(1) RP A type (2) RXA type.......................................................................................................... 62

(3) RSA/RSW type (4) RMA/RMW type ..................................................................................... 63

(5) RFA/RFW type......................................................................................................................64

6.2 Explanation of Modes................................................................................................................... 65

6.2.1 Positioning Mode Push = 0 ................................................................................................... 65

6.2.2 Push & Hold Mode Push = Other than 0...............................................................................65

6.2.3 Speed Change during Movement..........................................................................................67

6.2.4 Operation at Different Acceleration and Deceleration Settings.............................................67

6.2.5 Pause ....................................................................................................................................68

6.2.6 Zone Signal Output ............................................................................................................... 69

6.2.7 Home Return......................................................................................................................... 69

6.2.8 Teaching Mode (Jogging/Teaching Using PIO).....................................................................70

6.2.9 Overview of the “4 Points” (Air Cylinder) Mode.....................................................................71

6.3 Notes on the ROBO Gripper........................................................................................................73

7. Operation <Practical Steps>..............................................................75

7.1 How to Start..................................................................................................................................75

7.1.1 Standard Specification........................................................................................................... 75

7.1.2 Absolute Specification (Absolute Reset)............................................................................... 77

7.2 How to Execute Home Return......................................................................................................80

7.2.1 Standard Specification........................................................................................................... 80

7.2.2 Absolute Specification........................................................................................................... 81

7.2.3 Operation Timings at PIO Pattern = “0: [Conventional]”........................................................82

7.2.4 Operation Timings at PIO Pattern = “5: [4 Points]”................................................................83

7.2.5 Operation Timings at PIO Pattern ≠ “0: [Conventional]” or “5: [4 Points]”..........................84

7.3 Home Return and Movement after Start (PIO Pattern = “1: [Standard]”)..................................85

7.4 Positioning Mode (Back and Forth Movement between Two Points)...........................................87

7.5 Push & Hold Mode .......................................................................................................................89

7.5.1 Return Action after Push & Hold by Relative Coordinate Specification ................................90

7.6 Speed Change during Movement.................................................................................................91

7.7 Operation at Different Acceleration and Deceleration Settings.................................................... 93

7.8 Pause ...........................................................................................................................................95

7.9 Zone Signal Output ......................................................................................................................97

.10 Incremental Moves.......................................................................................................................99

7.11 Notes on Incremental Mode....................................................................................................... 101

7.12 Jogging/Teaching Using PIO...................................................................................................... 103

8. Parameters ......................................................................................109

8.1 Parameter Classification ............................................................................................................109

8.2 Parameter Table.........................................................................................................................109

8.3 Parameter Settings..................................................................................................................... 110

8.3.1 Parameters Relating to the Actuator S troke Range............................................................ 110

 Soft limit............................................................................................................................... 110

 Zone boundary.................................................................................................................... 110

 Home return direction...........................................................................................................111

 Home return offset................................................................................................................111

8.3.2 Parameters Relating to the Actuator Operating Characteristics..........................................111

 PIO jog speed.......................................................................................................................111

 Default speed.......................................................................................................................111

 Default acceleration/deceleration.........................................................................................111

 Default positioning band (in-position).................................................................................. 112

 Default acceleration only MAX flag..................................................................................... 112

 Push & hold stop judgment period...................................................................................... 112

 Current-limiting value at standstill during positioning.......................................................... 113

 Current-limiting value during hom e return........................................................................... 113

 Direction of excitation phase signal detection..................................................................... 113

8.3.3 Parameters Relating to the External Interface.................................................................... 114

 PIO pattern selection........................................................................................................... 114

 Movement co mmand type................................................................................................... 115

 Pause input disable selection.............................................................................................. 116

 Servo ON input disable selection........................................................................................ 116

 Serial communication speed............................................................................................... 116

 Minimum delay time for slave transmitter activation........................................................... 116

8.3.4 Servo Gain Adjustment........................................................................................................ 116

 Servo gain number.............................................................................................................. 116

9. Controlling Multiple Controllers via Serial Communication ..............117

9.1 Basic Specifications.................................................................................................................... 117

9.2 Connection Example..................................................................................................................117

9.3 SIO Converter ............................................................................................................................ 118

9.4 Address Switch...........................................................................................................................120

9.5 Connection Cables.....................................................................................................................120

9.6 Detail Connection Diagram ........................................................................................................121

10. Troubleshooting...............................................................................122

10.1 Action to Be Taken upon Occurrence of Problem......................................................................122

10.2 Alarm Level Classification..........................................................................................................123

10.3 Alarm Description Output Using PIO..........................................................................................124

10.4 Alarm Description and Cause/Action .........................................................................................125

(1) Message level alarms..........................................................................................................125

(2) Operation-cancellation level alarms.................................................................................... 126

(3) Cold-start level alarms.........................................................................................................129

10.5 Messages Displayed during Operation Using the Teaching Pendant or PC Software .............. 131

10.6 Specific Problems.......................................................................................................................133

 I/O signals cannot be exchanged with the PLC. .................................................................133

 The RDY lamp does not illuminate after the power is input................................................133

 Only the RDY lamp illuminates when the servo ON signal is input after the power was input.133

 Both the RDY lamp and ALM lamp illuminate when the power is input.............................. 133

 Home return ends in the middle in a vertical application. ................................................... 134

 Noise occurs during downward movements in a vertical application..................................134

 Vibration occurs when the actuator is stopped. ..................................................................134

 The actuator overshoots when decelerated to a stop.........................................................134

 The home and target positions sometimes shift..................................................................134

 The speed is slow during push & hold operation................................................................134

 The actuator moves only a half of, or twice as much as, the specified movement.............135

 A servo error occurred while the actuator was moving (ROBO Gripper)............................135

 Abnormal operation results when the servo is turned ON after the power ON................... 136

 Abnormal noise is heard from a controller of absolute specification upon completion of home return.

.............................................................................................................................................136

 The ALM lamp blinks when the power is cut off..................................................................136

11. Function Check and Replacement of the Radiating Fan .................137

12. Replacing the Absolute Data Retention Battery...............................139

* Appendix.................................................................................................141

List of Supported Actuator Specifications..................................................141

Example of Basic RCP2 Positioning Sequence........................................151

Recording of Position-Data Table...........................................................................................................154

Recording of Parameters....................................................................................................................... 156

Change History.........................................................................................157

Safety Guide

This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and prope rty damage. Be sure to read this section before using your product.

Regulations and Standards Governing Industrial Robots

Safety measures on mechanical devices are generally classified into four categori es un der the International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows:

Safety measures Inherent safety design

Protective guards --- Safety fence, etc. Additional safety measures --- Emergency stop device, etc. Information on use --- Danger sign, warnings, operation manual

Based on this classification, various standards are established in a hierarchical manner under the International Standards ISO/IEC. The safety standards that apply to industrial robots are as follows:

Type C standards (individual safety standards) ISO10218 (Manipulating industrial robots – Safety)

JIS B 8433 (Manipulating industrial robots – Safety)

Also, Japanese laws regulate the safety of industrial robots, as follows: Industrial Safety and Health Law Article 59

Workers engaged in dangerous or harmful operations must receive special education.

Ordinance on Industrial Safety and Health Article 36 --- Operations requiring special education

No. 31 (Teaching, etc.) --- Teaching and other similar work involving industrial robots (exceptions

apply)

No. 32 (Inspection, etc.) --- Inspection, repair, adjustment and similar work involving industrial robots

(exceptions apply)

Article 150 --- Measures to be taken by the user of an industrial robot

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Requirements for Industrial Robots under Ordinance on Industrial Safety and

Health

Work area

movement

range

Inside

movement

range

Work

condition

During

automatic

operation

During

teaching, etc.

During

inspection,

etc.

Cutoff of drive source Measure Article

Signs for starting operation Article 104 Outside

Not cut off

Cut off (including

stopping of operation)

Not cut off

Cut off

Not cut off (when

inspection, etc., must

be performed during

operation)

Installation of railings, enclosures, etc. Sign, etc., indicating that work is in progress Preparation of work rules Article 150-3 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education Article 36-31 Checkup, etc., before commencement of work To be performed after stopping the operation Sign, etc., indicating that work is in progress Preparation of work rules Article 150-5 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education (excluding cleaning and lubrication)

Article 150-4 Article 150-3

Article 150-3 Article 150-3

Article 151 Article 150-5 Article 150-5

Article 150-5 Article 150-5 Article 36-32

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Applicable Modes of IAI’s Industrial Robot

Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No. 340):

(1) Single-axis robo with a motor wattage of 80 W or less (2) Combined multi-axis robot whose X, Y and Z-axes are 300 mm or shorter and whose rotating part, if

any, has the maximum movement range of within 300 mm

(3) Multi-joint robot whose movable radius and Z-axis are within 300 mm

Among the products featured in our catalogs, the following models are classified as industrial robots:

1. Single-axis ROBO Cylinders RCS2/RCS2CR-SS8 whose stroke exceeds 300 mm

2. Single-axis robots The following models whose stroke exceeds 300 mm and whose motor capacity also exceeds 80 W: ISA/ISPA, ISDA/ISPDA, ISWA/ISPWA, IF, FS, NS

3. Linear servo actuators All models whose stroke exceeds 300 mm

4. Cartesian robots Any robot that uses at least one axis corresponding to one of the models specified in 1 to 3

5. IX SCARA robots

All models whose arm length exceeds 300 mm (All models excluding IX-NNN1205/1505/1805/2515, NNW2515 and NNC1205/1505/1805/2515)

including the end of the rotating part

Pre-3

Notes on Safety of Our Products

Common items you should note when performing each task on any IAI robot are explained below.

No. Task Note

1 Model

selection

2 Transportation

3 Storage/

preservation

4 Installation/

startup

 This product is not planned or designed for uses requiring high degrees of safety.

Accordingly, it cannot be used to sustain or support life and must not be used in the

following applications: [1] Medical devices relating to maintenance, management, etc., of life or health [2] Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities, etc.)

intended to move or transport people [3] Important safety parts in mechanical devices (safety devices, etc.)  Do not use this product in the following environments: [1] Place subject to flammable gases, ignitable objects, flammables, explosives, etc. [2] Place that may be exposed to radiation [3] Place where the surrounding air temperature or relative humidity exceeds the specified

range [4] Place subject to direct sunlight or radiated heat from large heat sources [5] Place subject to sudden temperature shift and condensation [6] Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.) [7] Place subject to excessive dust, salt or iron powder [8] Place where the product receives direct vibration or impact  Do not use this product outside the specified ranges. Doing so may significantly

shorten the life of the product or result in product failure or facility stoppage.

 When transporting the product, exercise due caution not to bump or drop the product.  Use appropriate means for transportation.  Do not step on the package.  Do not place on the package any heavy article that may deform the package.  When using a crane of 1 ton or more in capacity, make sure the crane operators are

qualified to operate cranes and perform slinging work.  When using a crane, etc., never hoist articles exceeding the rated load of the crane,

etc.  Use hoisting equipment suitable for the article to be hoisted. Calculate the load needed

to cut off the hoisting equipment and other loads incidental to equipment operation by

considering a safety factor. Also check the hoisting equipment for damage.

 Do not climb onto the article while it is being hoisted.  Do not keep the article hoisted for an extended period of time.  Do not stand under the hoisted article.

 The storage/preservation environment should conform to the installation environment.

Among others, be careful not to cause condensation. (1) Installing the robot, controller, etc.

 Be sure to firmly secure and affix the product (including its work part).

If the product tips over, drops, malfunctions, etc., damage or injury may result.  Do not step on the product or place any article on top. The product may tip over or the

article may drop, resulting in injury, product damage, loss of/drop in product

performance, shorter life, etc.  If the product is used in any of the following places, provide sufficient shielding

measures: [1] Place subject to electrical noise [2] Place subject to a strong electric or magnetic field [3] Place where power lines or drive lines are wired nearby [4] Place subject to splashed water, oil or chemicals

Pre-4

No. Task Note

4 Installation/

startup

(2) Wiring the cables  Use IAI’s genuine cables to connect the actuator and controller or connect a teaching

tool, etc.  Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place

heavy articles on top. Current leak or poor electrical continuity may occur, resulting in

fire, electric shock or malfunction.

 Wire the product correctly after turning off the power.  When wiring a DC power supply (+24 V), pay attention to the positive and negative

polarities.

Connecting the wires in wrong polarities may result in fire, product failure or

malfunction.  Securely connect the cables and connectors so that they will not be disconnected or

come loose. Failing to do so may result in fire, electric shock or product malfunction.  Do not cut and reconnect the cables of the product to extend or shorten the cables.

Doing so may result in fire or product malfunction. (3) Grounding

 Be sure to provide class D (former class 3) grounding for the controller. Grounding is

required to prevent electric shock and electrostatic charges, improve noise resistance

and suppress unnecessary electromagnetic radiation. (4) Safety measures

 Implement safety measures (such as installing safety fences, etc.) to prevent entry into

the movement range of the robot when the product is moving or can be moved.

Contacting the moving robot may result in death or serious injury.  Be sure to provide an emergency stop circuit so that the product can be stopped

immediately in case of emergency during operation.  Implement safety measures so that the product cannot be started only by turning on the

power. If the product starts suddenly, injury or product damage may result.  Implement safety measures so that the product will not start upon cancellation of an

emergency stop or recovery of power following a power outage. Failure to do so may

result in injury, equipment damage, etc.  Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc.,

during installation, adjustment, etc. If the power is accidently turned on, electric shock

or injury may result.  Implement measures to prevent the work part, etc., from dropping due to a power

outage or emergency stop.  Ensure safety by wearing protective gloves, protective goggles and/or safety shoes, as

necessary.  Do not insert fingers and objects into openings in the product. Doing so may result in

injury, electric shock, product damage, fire, etc.  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged work part,

etc.

5 Teaching

 Whenever possible, perform teaching from outside the safety fences. If teaching must

be performed inside the safety fences, prepare “work rules” and ma ke sure the

operator understands the procedures thoroughly.  When working inside the safety fences, the operator should carry a handy emergency

stop switch so that the operation can be stopped any time when an abnormality occurs.  When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality occurs.

The safety watcher must also make sure the switches are not operated inadvertently by

a third party.  Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.

Pre-5

No. Task Note

5 Teaching  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged load, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

6 Confirmation

operation

 After teaching or programming, carry out step-by-step confirmation operation before

switching to automatic operation.  When carrying out confirmation operation inside the safety fences, follow the specified

work procedure just like during teaching.  When confirming the program operation, use the safety speed. Failure to do so may

result in an unexpected movement due to programming errors, etc., causing injury.  Do not touch the terminal blocks and various setting switches while the power is

supplied. Touching these parts may result in electric shock or malfunction.

7 Automatic

operation

 Before commencing automatic operation, make sure no one is inside the safety fences.  Before commencing automatic operation, make sure all related peripherals are ready to

operate in the auto mode and no abnormalities are displayed or indicated.

 Be sure to start automatic operation from outside the safety fences.  If the product generated abnormal heat, smoke, odor or noise, stop the product

immediately and turn off the power switch. Failure to do so may result in fire or product

damage.  If a power outage occurred, turn off the power switch. Otherwise, the product may

move suddenly when the power is restored, resulting in injury or product damage.

8 Maintenance/

inspection

 Whenever possible, work from outside the safety fences. If work must be performed

inside the safety fences, prepare “work rules” and make sure the operator understands

the procedures thoroughly.

 When working inside the safety fences, turn off the power switch, as a rule.  When working inside the safety fences, the operator should carry a handy emergency

stop switch so that the operation can be stopped any time when an abnormality occurs.  When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality occurs.

The safety watcher must also make sure the switches are not operated inadvertently by

a third party.

 Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.  Use appropriate grease for the guides and ball screws by checking the operation

manual for each model.  Do not perform a withstand voltage test. Conducting this test may result in product

damage.  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged work part,

etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

9 Modification  The customer must not modify or disassemble/assemble the product or use

maintenance parts not specified in the manual without first consulting IAI.  Any damage or loss resulting from the above actions will be excluded from the scope of

warranty.

10 Disposal  When the product becomes no longer usable or necessary, dispose of it properly as an

industrial waste.  When disposing of the product, do not throw it into fire. The product may explode or

generate toxic gases.

Pre-6

Indication of Cautionary Information

The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and “Note,” as specified below.

Level Degree of danger/loss Symbol

Danger

Warning

Caution

Note

Failure to observe the instruction will result in an imminent danger leading to death or serious injury.

Failure to observe the instruction may result in death or serious injury.

Failure to observe the instruction may result in injury or property damage.

The user should take heed of this information to ensure the proper use of the product, although failure to do so will not result in injury.

Danger

Warning

Caution

Note

Pre-7

Pre-8

1. Overview

1.1 Introduction

Thank you for purchasing the RCP2 controller. This manual explains the features and operating procedures of the product.

If not used or handled properly, even a brilliant product cannot fully demonstrate its function or may cause an unexpected breakdown or end its life prematurely. Please read this manual carefully and handle the product with utmost care while ensuring its correct operation. Keep this manual in a convenient place so the relevant sections can be referenced readily when necessary.

If you are also using any of IAI’s various actuators and/or optional PC software or teaching pendant, also refer to the operation manual for each item.

1.2 How to Read Model Number

 Controller with a power-supply capacity of 2 A

C: Built-in cutoff relay CG: External cutoff relay

Slider, ball-screw type

Slider, belt type

Rod type

Rod, splash-proof type

<Absolute battery bracket> Blank: Without bracket K: With bracket

<I/O signal type> Blank: NPN (sink type) P: PNP (source type)

<Motor type> PM: Pulse motor

<Encoder type> I: Incremental

: Absolute

Gripper

Rotary

 Controller with a power-supply capacity of 6 A (Large-capacity type)

CF: Built-in cutoff relay

High-speed ball-screw type High-thrust rod type

Waterproof type

<I/O signal type> Blank: NPN (sink type) P: PNP (source type)

<Motor type> PM: Pulse motor

<Encoder type> I: Incremental

1.3 Handling of Secondary Batteries for the Absolute Specification

Observe the safety precautions specified below when handling the secondary batteries:

1. Never attempt to disassemble the batteries. Strong alkali battery fluid will damage the skin or clothes.

2. Never short the battery terminals (i.e. by allowing the positive and negative terminals to make direct contact). Doing so may damage the equipment or cause burns due to the generatio n of heat.

3. Never throw the batteries into a fire, because it may cause them to explode. Also avoid immersing the batteries in water, which can result in loss of battery function.

4. Do not solder the batteries directly. The safety valve inside the battery cap may be damaged, resulting in a breakdown of the safety mechanism.

5. If the battery connector remains connected for a long time without a supply of power, a deep discharge may occur and cause the battery fluid to leak or allow the battery performance or life to deteriorate/shorten significantly. If the equipment is to be relocated or modified and the power will not be supplied for a prolonged period, first disconnect the battery connector.

6. When disposing of used batteries, drop them into the collection box at an authorized recycle store or take other appropriate steps.

* We have made every effort to ensure accuracy of the information provided in this manual. Should you find an

error, however, or if you have any comment, please contact IAI.

Keep this manual in a convenient place so it can be referen ce d re adily when necessary.

1.4 Safety Precautions

Read the following information carefully and provide safety measures with due consideration.

This system product has been developed as a drive component for automated machinery and the like, and is therefore designed not to generate excessive torque or speed beyond the levels needed to drive automated equipment. However, the following instructions must be strictly observed to prevent an unexpected accident.

1. Do not handle this product in any manner not specified in this manual. If you have questions regarding any of the information provided in this manual, please contact IAI.

2. Always use the specified genuine parts to wire your RCP2 controller and an actuator.

3. Do not enter the operating range of the machine while the machine is operating or is able to operate (the controller power is ON). If the machine is used in a place accessible to other people, enclo se its operating range using a safety cage, etc.

4. Always turn off the power supply to the controller before assembling/adjusting or maintaining/inspecting the machine. During assembly/adjustment or maintenance/inspection, put a plate or other visible sign in a conspicuous place indicating that work is in progress. The operator should ke ep the entire power cable beside him or her to prevent another person from inadvertently plugging in the cable.

5. If two or more persons work together, set signaling methods so each person can confirm the safety of other(s) during work. Especially when the work requires an axis or axes to be moved—with or without the power and by motor drive or manual operation—the person moving each axis should always call out beforehand to ensure safety.

6. If you have extended a cable or made other alteration to the standard wiring specification, thoroughly check the wiring and ensure absence of problem before turning on the power, in order to prevent malfunction due to miswiring.

1.5 Warranty Period and Scope of Warranty

The RCP2 controller you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The unit is covered by the following warranty:

1. Warranty Period The warranty period shall be one of the following periods, whichever ends first:

 18 months after shipment from our factory  12 months after delivery to a specified location

2. Scope of Warranty If an obvious manufacturing defect is found during the above period under an appropriate co ndition of use, IAI will repair the defect free of charge. Note, however, that the following items are excluded from the scope of warranty:

 Aging such as natural discoloration of coating  Wear of a consumable part due to use  Noise or other sensory deviation that doesn’t affect the mechanical function  Defect caused by inappropriate handling or use by the user  Defect caused by inappropriate or erroneous maintenance/inspection  Defect caused by use of a part other than IAI’s genuine part  Defect caused by an alteration or other change not approved by IAI or its agent  Defect caused by an act of God, accident, fire, etc.

The warranty covers only the product as it has been delivered and shall not cover any losses arising in connection with the delivered product. The defective product must be brought to our factory for repair.

Please read carefully the above conditions of warranty.

2. Specifications

2.1 Basic Specifications

Specification item

RCP2-C-*** (Note) RCP2-CG-*** (Note) Number of controlled axes 1 axis/unit

Internal Drive-Power Cutoff Relay

Type

External Drive-Power Cutoff

Relay Type

Supply voltage Supply current 2 A max. Control method Weak field-magnet vector control (patent pending) Encoder resolution 800 P/rev

Positioning command Position number Standard 16 points, maximum 64 points

Backup memory

PIO LED indicators RDY (green), RUN (green), ALM (red)

Communication RS485 1 channel (terminated externally) Encoder interface Incremental specification conforming to EIA RS-422A/423A

Forced release of electromagnetic brake

Cable length

Isolation strength Environment Surrounding humidity 85%RH or less (non-condensing)

Storage temperature

Surrounding air temperature

Surrounding environment

24 VDC 10%

Position number specification Direct specification

Position number data and parameters are saved in nonvolatile memory. Serial EEPROM can be rewritten 100,000 times. 10 dedicated inputs/10 dedicated outputs. Selectable from five patterns.

Toggle switch on front panel of enclosure Actuator cable: 20 m or less

PIO cable: 5 m or less 500 VDC, 10 M

0 to 40C

Not subject to corrosive gases.

-10 to 65C

Storage humidity 90%RH or less (non-condensing) Vibration resistance Protection class IP20

Weight 300 g or less External dimensions 35 W x 178.5 H x 68.1 D mm

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

(Note) *** indicates the actuator type.

2.1.1 Backup Batteries for the Absolute Specification

The absolute-specification controller uses secondary batteries (nickel metal hydride cells) to retain absolute counter data in the FPGA (field-programmable gate array) after the power is cut off, and also to supply power to the encoder’s drive circuit intermittently.

(1) Battery specification

Item Description Classification Cylindrical sealed nickel metal hydride cell Manufacturer Matsushita Battery Industrial

Model number AB-4

Nominal voltage 4.8 V (1.2 V x 4)

Rated capacity 1900 mAh (average capacity: 2050 mAh)

Average life Approx. 3 years

Charging time

Retention time after power cutoff

(2) Charging the batteries

Be sure to charge the batteries when the controller is powered up for the first time after delivery, and also after new batteries have been installed. The batteries are charged automatically while the power is being supplied to the controller, so keep the main power on for at least 48 hours. The actuator can be moved and the position table changed while the batteries are ch arging. Additionally, charge the batteries for at least 48 hours after the power supply to the controller has been cut off for a prolonged period (within the specified battery-retention time).

(3) Replacing the batteries

Batteries are consumable parts. Repeated charging and discharging of the batteries will diminish their initial performance characteristics. If the retention time has decreased significantly, the batteries may have reached the end of their useful life. If this should occur, replace the batteries. The batteries should be replaced approximately three years after the controller is first connected to your equipment, although the specific timing will vary depending on the surrounding air temperature and conditions of charge/discharge. The label on the battery unit shows a reference date, which is three years from the shipment date. Use this date to determine when the batteries should be replaced.

Approx. 48 hours (at surrounding air temperature of 20C) Approx. 250 hours (when the batteries are fully charged, at surrounding air temperature of 20C)

Note: (1) Applying vibration, impact or other external force to the actuator or moving the slider, etc.,

while the power is off will erase the absolute data.

When the power is input again, the *ALM signal will turn OFF, the ALM lamp will illuminate

and the message “Absolute encoder error (2)” or “Absolute encoder error (3)” will be

displayed. In this case, you must reset the alarm and perform a home return. Never move the slider or rod while the power is off! (2) It is recommended that the batteries be charged at normal temperature (+10 to +30C) to

prevent extreme temperatures from negatively affecting the charging efficiency. Temperatures exceeding 45C may cause performance deterioration or the leakage of

battery fluid.

2.1.2 Specifications of the Large-Capacity Type (RCP2-CF)

Specification item Internal Drive-Power Cutoff Relay Type Model number RCP2-CF-*** Number of controlled axes 1 axis/unit Supply voltage Supply current 6 A max. Control method Weak field-magnet vector control (patent pending) Encoder resolution 800 P/rev

Positioning command Position number Standard 16 points, maximum 64 points

Backup memory

PIO LED indicators RDY (green), RUN (green), ALM (red)

Communication RS485 1 channel (terminated externally) Encoder interface Incremental specification conforming to EIA RS-422A/423A

Forced release of electromagnetic brake

Cable length

24 VDC 10%

Position number specification Direct specification

Position number data and parameters are saved in nonvolatile memory. Serial EEPROM can be rewritten 100,000 times. 10 dedicated inputs/10 dedicated outputs. Selectable from five patterns.

Toggle switch on front panel of enclosure Actuator cable: 20 m or less

PIO cable: 5 m or less

Isolation strength

Environment

Surrounding humidity 85%RH or less (non-condensing)

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

Vibration resistance Protection class IP20

Weight 300 g or less External dimensions 35 W x 180 H x 71.6 D mm

Surrounding air temperature

Surrounding environment

500 VDC, 10 M 0 to 40C

Not subject to corrosive gases.

-10 to 65C

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

2.2 Name and Function of Each Part of the Controller

2.2.1 Names

[2] Status indicator LEDs

RDY (green)  RUN (green)  ALM (red)

[3] PIO pattern number label

[4] Teaching pendant/ PC connector

[6] Power/emergency-stop

terminal block

2.2.2 Functions

[1] Battery connector A connector for the absolute data retention batteries.

[2] Status indicator LEDs

RDY: When lit, this LED indicates that 24V power is supplied and the CPU is operating. RUN: This LED indicates the servo status. Lit = Servo is ON, Unlit = Servo is OFF. ALM: When lit, this LED indicates that an alarm is present, or an emergency stop has been actuated or the

motor drive power is cut off. With the absolute specification controller, a blinking ALM LED indicates that the battery voltage has dropped to approx. 4.1 V or below when the power is cut off.

[3] PIO pattern number label (IOPN) Write down the PIO pattern selected in parameter No. 25 on this label. (This will facilitate maintenance if multiple controllers are used in different patterns.)

[4] Teaching pendant/PC connector (SIO) A connector for the dedicated teaching pendant or PC communication cable. This cable is also used to link two or more controllers to enable serial communication among them.

[1] Battery connector

(absolute specification)

[5] Motor connector

[7] I/O signal connector

[8] Address switch [9] PORT switch

[10] Encoder connector

[11] Brake release switch

[5] Motor connector (MOT) A connector for the actuator’s motor power cable.

[6] Power/emergency-stop terminal block [Built-in cutoff relay type RCP2-C, RCP2-CF]

Provide a contact output for the emergency-stop button on the teaching pendant.

S1, S2

Port switch ON = Emergency-stop button output (Contact B) Port switch OFF = ON in normal conditions of use (Emergency-stop button output is disabled) Provide a contact for cutting off the motor drive power. MPI and MPO represent the

MPI, MPO

input side and output side of the motor power supply, respectively. (Short these terminals using a jumper wire if not used. The controller is shipped with MPI and MPO shorted.)

24V Positive side of the 24-V power supply

N Negative side of the 24-V power supply

EMG Emergency-stop input

[External cutoff relay type RCP2-CG]

Provide a contact output for the emergency-stop button on the teaching pendant.

S1, S2

MPI, MPO

input side and output side of the motor power supply, respectively. (Connect an external safety circuit.)

24V Positive side of the 24-V power supply

N Negative side of the 24-V power supply

FG FG of the 24-V power supply

[7] I/O signal connector (PIO) A PIO cable connector to the host controller (PLC, etc.).

[8] Address switch (ADRS) A switch for setting the address for the controller axis. If two or more controllers are connected in the serial communication mode, do not specify duplicate controller addresses.

Setting range: 0 to F (A maximum of 16 controllers can be connected.)

[9] PORT switch (PORT) A switch for enabling/disabling the serial communication port. Set this switch to ON when connecting the controller to a teaching pendant or PC. Set it to OFF if no teaching pendant or PC is connected. * If this switch is turned ON without connecting a teaching pendant or PC, an emergency stop will be actuated.

[10] Encoder connector (ENC) A connector for the actuator’s encoder/brake cables.

[11] Brake release switch (BK) A switch for forcibly releasing the brake when the actuator is used with a brake option.

RLS: Brake is forcibly released NOM: Normal setting (Brake is controlled by the controller)

2.3 External Dimensions

2.3.1 Standard Specification (RCP2-***-I )

An external view and dimensions of the product are shown below.

(Mounting dimension)

2.3.2 Absolute Specification with Battery Bracket (RCP2-***-A- -K)

(Mounting dimension)

*Weight: 660 g

Absolute Specification without Battery Bracket (RCP2-***-A- )

(Mounting dimension)

*Weight: 460 g

2.3.3 Large-Capacity Type (RCP2-CF-***)

Built-in radiating fan

*Weight: 250 g

(Mounting dimension)

3. Installation and Noise Elimination

Pay due attention to the installation environment of the controller.

3.1 Installation Environment

(1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient ventilation

will not only prevent the controller from demonstrating its full performance, but it may also cause breakdown.)

(2) Prevent foreign matter from entering the controller through the ventilation holes. Since the enclosure of the

controller is not dustproof or waterproof (oilproof), avoid using the controller in a place subject to significant dust, oil mist or splashes of cutting fluid.

(3) Do not expose the controller to direct sunlight or radiating heat from a large heat source such as a heat

treatment furnace.

(4) Use the controller in an environment free from corrosive or inflammable gases, under a temperature of 0 to

40C and humidity of 85% or less (non-condensing). (5) Use the controller in an environment where it will not receive any external vibration or shock. (6) Prevent electrical noise from entering the controller or its cables.

3.2 Power Supply

The power supply specification is 24 VDC  10%. (Supply current: 2 A max.)

3.3 Noise Elimination and Grounding

This section explains how to eliminate noise in the use of the controller.

(1) Wiring and power supply

[1] Provide a dedicated class D grounding using a wire with a size of 2.0 to 5.5 mm2 or larger.

Controller

Other

equipment

Controller

Use a cable of a maximum possible size and keep the wiring length at a minimum.

Metal frame

Class D grounding Good Avoid this grounding method.

Other

equipment

[2] Precautions regarding wiring method Use a twisted cable for connection to the 24-VDC external power supply.

Separate the controller cables from high-power lines such as a cable connecting to a power circuit. (Do not bundle together the controller cables with high-power lines or place them in the same cable duct.) When extending the supplied motor cable or encoder cable, consult IAI’s Technical Support.

(2) Noise sources and elimination

Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular concern when building a system. Noise from these sources can be eliminated by implementing the measures specified below.

[1] AC solenoid valves, magnet switches and relays Measure: Install a surge absorber in parallel with the coil.

[2] DC solenoid valves, magnet switches and relays Measure: Install a diode in parallel with the coil. Determine the diode capacity in accordance with the load

capacity.

 Point

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

In a DC circuit, connecting a diode in reverse polarity will damage the diode, internal parts of the controller and/or DC power supply, so exercise due caution.

3.4 Heat Radiation and Inst allation

Design the control panel size, controller layout and cooling method in such a way that the temperature around the controller will not exceed 40C.

Install the controller vertically on a wall, as shown below. Since cooling is provided by way of natural convection, always observe this installation direction and provide a minimum clearance of 50 mm above and below the controller to ensure sufficient natural airflows.

When installing multiple controllers side by side, providing a ventilation fan or fans above the controllers will help maintain a uniform temperature around the controllers.

Keep the front panel of the controller away from the wall (enclosure) by at least 95 mm.

Regardless of whether your system consists of a single controller or multiple controllers, provide sufficient clearances around each controller so that it can be installed/removed easily.

In the case of the large-capacity type, extra space is required to release the exhaust heat from the radiating fan. Therefore, provide a clearance of 15 mm or more for this controller type.

Fan

50 mm or more

95 mm

or more

Airflow

4. Wiring

4.1 Internal Drive-Power Cutoff Relay Type (RCP2-C, RCP2-CF)

4.1.1 Configuration

Standard teaching pendant

<RCA-T>

Cable length: 5 m

<RCB-105-2> Cable length: 2 m <RCB-105-5> Cable length: 5 m

External unit

Optional

PC software

<RCB-101-MW>

Optional

External EMG switch

Input power supply 24V

24 VDC 0

Supplied flat

cable

Cable length: 2 m

Host system <PLC>

* If the PLC is not used,

disable the servo ON input and pause input using the applicable parameters.

ROBO cylinder

Cable length: 5 m

Optional

Do not connect or disconnect the connectors while the

S1 S2 MPI MPO 24V N EMG

power is on, except for the communication port connector (SIO). To connect or disconnect the SIO, do so after turning off the PORT switch. Failure to do so may result in breakdown.

Note: Connect one end of the EMG switch to the 24-V output of the input power supply and the

other end to the S1 terminal. Also short the S2 and EMG terminals using a jumper wire.

4.1.2 External Connection Diagram

An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable for the controller with the maximum

current of 2 A.

As for the robot cable or the cable for the large-capacity type, refer to 4.4.2, “Encoder Extension Cable.”

Connected to teaching pendant or PC

External EMG switch

Input power supply 24 VDC 24V 0V FG

Host system

flat cable

Refer to 4.3, “Connecting the I/O Cables,” for the connection of I/O signals.

Terminal block

Controller

(PORT switch)

Blue

Black

White

Red Black Green

Yellow

Orange (black 2)

Orange (red 2)

Yellow (black 1)

Yellow (red 1)

White (black 1)

White (red 1)

Light blue (black 1)

Light blue (red 1)

Brake release switch

Tighten together with the mounting screw.

Actuator

Motor

Encoder

Holding brake

4.1.3 Wiring the Power Supply/Emergency-Stop Switch

(1) Wiring the power supply

Input power supply 24 VDC

(2 A max. per controller)

24V 0V FG

To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications:

Item Specification

Applicable wire length

Single wire: 1.0 / Stranded: 0.8 mm

Stripped wire length 10 mm Temperature rating of

insulating sheath

60C or above

* Use a flathead screwdriver with a blade tip of approx. 2.6 mm to push in the wire.

 Notes on wiring the absolute-specification controller [1] When connecting a relay to the 24-V line, be sure to install it on the positive side of the 24-V power su pply.

S2 MPI MPO

24V

N EMG

, AWG size 18 (copper wire)

Keep the negative side of the 24-V power supply connected without cutting it off with a relay. If a relay is installed on both the positive and negative sides, an ABS error may generate.

[2] Connect a surge killer to the relay contact.

Chattering of the relay may have negative effect on the controller. Connect a surge killer to prevent malfunction.

Surge killer

Recommended product: Spark Killer by Okaya Electric

Industries Model number: CR-50500 Capacitance: 0.5 F  20% Resistance: 50  (1/2W)  30%

RCP2ABS

24V+

24VPS

Relay

Do not install a relay on the negative side.

(2) Wiring the emergency-stop switch

In many cases multiple controllers are used in a single system. To provide an emergency-stop function for the entire system, the controller circuit is designed in su ch a way that a single EMG switch is able to actuate an emergency stop in all connected controllers.

[Internal emergency-stop circuit]

Teaching pendant

Input power supply (C: 2 A max.) (CF: 6 A max.)

24V 0V

EMG signal

MPI MPO

24V

EMG

OFF

PORT switch

Controller power supply

Relay

Motor power supply

(Note) The current consumption of the internal relay is 10 mA or less.

[Example of recommended circuit]

(Reference)

EMG switch on teaching pendant 30 VDC 3 A PORT switch 24 VDC 0.1 A

RCP2 controller

24V

EMG switch on

teaching pendant

External EMG

reset switch

External EMG

circuit

RCP2 controller

(3 A)

PORT switch

OFF

(0.1 A)

Cutoff voltage Cutoff current

Coil current:

0.1 A or less

MPI

MPO

24V EMG

Relay

(Note) To cut off the motor drive power supply in conformance with safety category 2, connect 24V to the EMG

terminal and a contactor or other contact device to the MPI/MPO terminals. (Refer to 4.2.3; rush current: 8 A.)

Representative connection examples are explained below.  Connecting the teaching pendant directly to the controller (Parallel connection with the PLC)

[1] Connecting multiple controllers (8 units or less) using a single power supply

 Short the MPI and MPO terminals using a jumper wire. (The controller is shipped with these terminals

shorted.)

 Connect one end of the EMG signal to the 24-V output of the input power supply and the other end to the S1

terminal. Then, provide connections by sequentially connecting the S2 terminal of controller 1 to the S1 terminal of controller 2, the S2 terminal of controller 2 to the S1 terminal of controller 3, and so on, and connect the S2 terminal on the last controller to the EMG terminals on all controllers. Use a relay terminal block for connection to the EMG terminals. (Note) Do not connect two or more wires to one terminal.

24V

EMG signal

[Controller 1]

Teaching pendant

S1 S2

MPI MPO

24V

EMG

[Controller 2]

Teaching pendant

S1 S2

MPI MPO

24V

EMG

[Controller 3]

Teaching pendant

S1 S2

MPI MPO

24V EMG

[Controller 4]

Teaching pendant

S1 S2

OFF

PORT switch

Relay

OFF

PORT switch

Relay

OFF

PORT switch

Relay

PORT switch

OFF

Relay

MPI MPO

24V

EMG

[2] Using a power supply other than the input power supply

(Note) Since the controller’s PORT switch has a cutoff capacity of 0.1 A, use an auxiliary relay with a coil

current of 0.1 A or less and connect a diode for coil surge absorption.

control

C 0V

power

P 24V

EMG signal

P 0V

[Controller 1]

Teaching pendant

S1 S2

MPI MPO

24V

EMG

OFF

PORT switch

Relay

[Controller 2]

Teaching pendant

S1 S2

MPI

MPO 24V N

EMG

OFF

PORT switch

Relay

[Controller 3]

Teaching pendant

MPI MPO

24V N

EMG

OFF

PORT switch

Relay

C 24V

[3] Enabling the EMG switch on the teaching pendant for the connected axis or axes only

24V

EMG signal

[Controller 1]

Teaching pendant

MPI MPO

24V EMG

PORT switch

[Controller 2]

Teaching pendant

MPI MPO

24V EMG

PORT switch

[Controller 3]

OFF

Relay

OFF

Relay

Teaching pendant

MPI MPO

24V EMG

PORT switch

OFF

Relay

 Connecting the teaching pendant to a SIO converter (Serial connection with the PLC) Configure the contact circuit for the EMG switch on the teaching pendant using EMG1/EMG2 on the

power/emergency-stop terminal block on the SIO converter. (S1/S2 on the controller’s terminal block are not used.)

24V

SIO converter

EMG signal

Teaching pendant

EMG2

EMG1

OFF

PORT switch

MPI MPO

24V EMG

MPI MPO

24V EMG

[Controller 1]

Relay

[Controller 2]

Relay

[Controller 3]

MPI MPO

24V EMG

Relay

4.2 External Drive-Power Cutoff Relay Type (RCP2-CG)

4.2.1 Configuration

<RCB-105-2> Cable length: 2 m <RCB-105-5> Cable length: 5 m

External unit

<RCB-101-MW>

Standard teaching pendant

<RCA-T>

Optional

Cable length: 5 m

Optional

PC software

Optional

Input power supply 24V 24 VDC 0

Safety relay contactor for motor drivepower cutoff circuit

Supplied flat

cable

Cable length: 2 m

S1 S2 MPI MPO 24V N FG

Host system <PLC>

* If the PLC is not used,

disable the servo ON input and pause input using the applicable parameters.

ROBO cylinder

Cable length: 5 m

Optional

Do not connect or disconnect the connectors while the power is on, except for the communication port connector (SIO). To connect or disconnect the SIO, do so after turning off the PORT switch. Failure to do so may result in breakdown.

4.2.2 External Connection Diagram

An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable.

As for the robot cable, refer to 4.4.2, “Encoder Extension Cable.”

Connected to teaching pendant or PC

Input power supply 24V 24 VDC 0V FG

Host system

Refer to 4.3, “Connecting the I/O Cables,” for the connection of I/O signals.

Motor drivepower cutoff circuit

flat cable

Controller

(PORT switch)

Terminal block

Blue

Black

White Red Black

Green

Yellow

Orange (black 2)

Orange (red 2)

Yellow (black 1)

Yellow (red 1)

White (black 1)

White (red 1)

Light blue (black 1)

Light blue (red 1)

Brake release switch

Actuator

Motor

Encoder

Holding brake

4.2.3 Wiring the Power Supply/Motor Power Cutoff Relay

(1) Wiring the power supply

Input power supply 24 VDC

(2 A max. per controller)

24V 0V FG

To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications:

Item Specification

Applicable wire length

Single wire: 1.0 / Stranded: 0.8 mm

Stripped wire length 10 mm Temperature rating of

insulating sheath

60C or above

* Use a flathead screwdriver with a blade tip of approx. 2.6 mm to push in the wire.

 Notes on wiring the absolute-specification controller [1] When connecting a relay to the 24-V line, be sure to install it on the positive side of the 24-V power su pply.

S2 MPI MPO

24V

N FG

, AWG size 18 (copper wire)

Keep the negative side of the 24-V power supply connected without cutting it off with a relay. If a relay is installed on both the positive and negative sides, an ABS error may generate.

[2] Connect a surge killer to the relay contact.

Chattering of the relay may have negative effect on the controller. Connect a surge killer to prevent malfunction.

Surge killer

Recommended product: Spark Killer by Okaya Electric

Industries Model number: CR-50500 Capacitance: 0.5 F  20% Resistance: 50  (1/2W)  30%

RCP2ABS

24V+

Relay

24VPS

Do not install a relay on the negative side.

(2) Wiring the motor power cutoff relay

Explained below is a safety circuit conforming to safety category 2. The user is responsible for implementing additional safety measures in the actual circuit configuration, such as providing double contactor contacts to prevent fusing.

The circuit illustrated below is for reference purposes only.  The input side of the motor drive power supply is connected to the MPI terminal, while the output side is

connected to the MPO terminal. Connect a contactor or other contact device to these terminals. (Note) The rush current must be 8 A or less. The rated current is 2 A.  The contact for the EMG switch on the teaching pendant is provided by the S1/S2 terminals. (Note) When connecting the teaching pendant to a SIO converter, the contact for the EMG switch on the

teaching pendant is provided by the EMG1/EMG2 terminals on the SIO converter.

[Example of basic circuit]

24V

External EMG

reset switch

External EMG

circuit

Coil current:

0.1 A or less MC

(Rush-in current: 8 A, rated current: 2 A)

(MAX. 2 A)

MPI

MPO

24V N

Teaching pendant

EMG switch

(3 A)

OFF

PORT switch

(0.1 A)

Motor power

supply Controller power supply

RCP2 controller

[Connection example of a multiple-axis configuration]

Input power supply

24V 0V FG

EMG signal

S33 S34

S11

Phoenix contact (PSR-SCP-24UC-/ESA2/4X1/1X2/B)

Safety relay unit

Connect to 24-V terminal Connect to N terminal Connect to FG terminal

[Controller 1] [Controller 2] [Controller 3]

S1 S2

MPI MPO 24V

N FG

S1 S2

MPI MPO 24V

N FG

Contactor

External reset switch

S12

S1 S2

MPI MPO

24V

4.3 Connecting the I/O Cables

 PIO pattern 0 [Conventional]

Host system <PLC> end

Command position 1 Command position 2

Command position 4 Command position 8

Output side

Completed position 1 Completed position 2 Completed position 4 Completed position 8

Input side

+24 [V]

0 [V] Start

Pause

Position complete

Home return

completion

Zone output

Alarm

Emergency stop

Upper stage

Lower stage

Brown 1 Red 1 Orange 1 Yellow 1 Green 1

Blue 1 Purple 1 Gray 1 White 1 Black 1 Brown 2 Red 2 Orange 2 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3

Note: The factory-set PIO pattern is [Conventional]. The pause signal may be disabled using parameter No. 15.

Blue 3

Brown 1

Controller end PIO (signal abbreviation)

1A P24 2A N 3A CSTR 4A PC1 5A PC2 6A PC4 7A PC8 8A

10A *STP 11A 12A

13A

1B 2B 3B PM1

4B PM2

5B PM4

6B PM8 7B PEND 8B HEND 9B ZONE

10B *ALM

11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”

12B

13B

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Lower stage

Upper stage

13A

13B

Note: When performing a continuity check of the flat cable, pay due attention not to expand the

female pins in the connector. It may cause contact failure and disable normal operation of the controller.

 PIO pattern 1 [Standard]

Host system <PLC> end

Command position 1 Command position 2 Command position 4 Command position 8

Output side

Completed position 1 Completed position 2 Completed position 4 Completed position 8

Input side

+24 [V]

0 [V]

Pause

Start

Home return

Servo ON

Reset

Zone output

Moving

Position complete

Home return

completion

Emergency stop

Ready

Alarm

Upper stage

Lower stage

Brown 1 Red 1 Orange 1

Yellow 1 Green 1 Blue 1 Purple 1 Gray 1 White 1 Black 1 Brown 2 Red 2 Orange 2 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3

Controller end PIO (signal abbreviation)

1A P24

2A N 3A PC1

4A PC2 5A PC4 6A PC8 7A 8A *STP 9A CSTR

10A HOME 11A SON 12A RES

13A

1B 2B 3B PM1

4B PM2

5B PM4

6B PM8

7B ZONE

8B MOVE

9B PEND

10B HEND

11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.” 12B SRDY

13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “1.” To enable the servo ON signal, be sure to set parameter No. 21 to “0.” The pause signal may

be disabled using parameter No. 15.

Blue 3

Lower stage

Upper stage

13A

13B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the

female pins in the connector. It may cause contact failure and disable normal operation of the controller.

 PIO pattern 2 [64-point positioning]

Host system <PLC> end

Command position 1 Command position 2 Command position 4

Command position 8 Command position 16 Command position 32

Output side

Completed position 1 Completed position 2 Completed position 4 Completed position 8

Completed position 16 Completed position 32

Input side

+24 [V]

0 [V]

Start

Home return

Pause

Reset

Position complete

Home return

completion

Emergency stop

Moving

Alarm

Upper stage

Lower stage

Brown 1 Red 1 Orange 1 Yellow 1 Green 1 Blue 1 Purple 1 Gray 1 White 1 Black 1 Brown 2 Red 2 Orange 2 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3

Controller end PIO (signal abbreviation)

1A P24 2A N 3A PC1 4A PC2 5A PC4 6A PC8 7A PC16 8A PC32 9A CSTR

10A HOME 11A *STP 12A RES 13A

1B 2B 3B PM1

4B PM2

5B PM4

6B PM8

7B PM16

8B PM32

9B PEND

10B HEND

11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.” 12B MOVE

13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “2.” The pause signal may be disabled using parameter No. 15.

Blue 3

Lower stage

Upper stage

13A

13B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the

female pins in the connector. It may cause contact failure and disable normal operation of the controller.

 PIO pattern 3 [2 zone output signals]

Host system <PLC> end

Command position 1 Command position 2

Command position 4 Command position 8

Output side

Completed position 1 Completed position 2

Completed position 4 Completed position 8

Input side

+24 [V]

0 [V]

Pause

Start

Home return

Servo ON

Reset

Zone output 1 Zone output 2

Position complete

Home return

completion

Emergency stop

Ready

Alarm

Upper stage

Lower stage

Controller end PIO (signal abbreviation)

1A P24 2A N 3A PC1

4A PC2

5A PC4

6A PC8 7A 8A *STP

9A CSTR

10A HOME 11A SON 12A RES

13A

1B 2B

3B PM1

4B PM2

5B PM4

6B PM8 7B ZONE1 8B ZONE2 9B PEND

10B HEND

11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.” 12B SRDY

13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “3.” To enable the servo ON signal, be sure to set parameter No. 21 to “0.” The pause signal may

be disabled using parameter No. 15.

Blue 3

Lower stage

Brown 1

Upper stage

13A

13B

Note: When performing a continuity check of the flat cable, pay due attention not to expand the

female pins in the connector. It may cause contact failure and disable normal operation of the controller.

 PIO pattern 4 [Teaching]

Host system <PLC> end

Command position 1 Command position 2

Command position 4 Command position 8

Output side

Start/Position write

Completed position 1 Completed position 2

Completed position 4 Completed position 8

Input side

+24 [V]

0 [V]

Operation mode

Pause/+Jog

Home return

Servo ON

Reset/–Jog

Current operation

Position complete/

Write completion

Emergency stop

mode

Moving

Home return

completion

Ready

Alarm

Upper stage

Lower stage

Controller end PIO (signal abbreviation)

1A P24

2A N 3A PC1

4A PC2 5A PC4 6A PC8 7A MODE 8A *STP/JOG +

9A CSTR/PWRT

10A HOME

11A SON 12A RES/JOG 13A

1B 2B

3B PM1

4B PM2

5B PM4

6B PM8 7B MODES

8B MOVE

9B PEND/WEND 10B HEND 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.” 12B SRDY

13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “4.” To enable the servo ON signal, be sure to set parameter No. 21 to “0.” Be sure to enable the pause signal using parameter No. 15 (by setting the parameter to “0”)

(the pause signal is enabled at the factory). The system cannot switch to the teaching mode if the pause signal is disabled (i.e., the above parameter is set to “1”).

Blue 3

Lower stage

Upper stage

13A

13B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the

female pins in the connector. It may cause contact failure and disable normal operation of the controller.

 PIO pattern 5 [4 points] (air cylinder)

Host system <PLC> end

Intermediate point Intermediate point

Output side

Rear end complete

Front end complete

Intermediate point Intermediate point

Input side

+24 [V]

0 [V]

Rear end move

Front end move

1 move 2 move

Pause

Reset

1 complete 2 complete

Zone output

Position complete

Home return

completion

Emergency stop

Alarm

Upper stage

Lower stage

Controller end PIO (signal abbreviation)

1A P24 2A N 3A ST0 4A ST1 5A ST2 6A ST3 7A 8A *STP

9A 10A 11A 12A RES

13A

3B PE0

4B PE1

5B PE2

6B PE3

7B ZONE

9B PEND

10B HEND

11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.” 12B

13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “5.” The pause signal may be disabled using parameter No. 15.

Blue 3

Lower stage

Upper stage

13A

13B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the

female pins in the connector. It may cause contact failure and disable normal operation of the controller.

4.4 Connecting the Actuator

4.4.1 Motor Extension Cable

 Connect the motor extension cable to the MOT connector.

Signal table for the controller-end connector (CN2)

Pin No. Signal Wire color Description

A A2 VMM Gray Motor power line A3

B B1 A Yellow Motor drive line (phase +A) B2 VMM Pink Motor power line

B3 B

Controller end

CN2 pin assignments

1 3

A B

Cable color Pin No.

Orange

Gray White

Yellow

Pink

Yellow (Black 1)

CN2

Signal

abbreviation

VMM

B A

VMM

Housing: 1-1318119-3 (AMP) Housing: SLP-06V (J.S.T. Mfg.) Receptacle contact: 1318107-1 Socket contact: BSF-21T-P1.4

Orange Motor drive line (phase –A)

White Motor drive line (phase –B)

Yellow

(Black 1)

CN2

A1 A2 A3

Motor drive line (phase +B)

CB-RCP2-MA * * *

Actuator end

CN1 pin assignments

CN1

Pin No. Cable color

CN1

Signal

abbreviation

2 3 4 5

VMM

A B

VMM

6 3

Yellow

Gray

Orange

Yellow (Black 1)

Pink White

4.4.2 Encoder Extension Cable  [Standard controller (2 A)]

 Connect the encoder extension cable to the ENC connector. Signal table for the controller-end connector (CN2)

Pin No. Signal abbreviation Description

1 F.G Shielded wire 2 - (Not used) 3 - (Not used) 4 - (Not used) 5 GND Encoder power output 6 5V 7 VPS Encoder control signal output 8 - (Reserved)

EN B

10 EN B 11

EN A 12 EN A 13 BK – Negative side of the brake power supply 14 BK + Positive side of the brake power supply 15 - (Reserved) 16 - (Reserved)

 Cable colors and pin assignments for units shipped in and after August 2004 (supporting the absolute

specification)

Controller end

CN2 pin assignments

CN2

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Cable color

Robot cable

Purple

White (with purple)

Blue

White (with blue)

Yellow

White (with yellow)

Green

Red

White (with red)

Ground

Standard cable

CN2

Red

Gray Brown Green Purple

Pink

Yellow

Orange

Blue

Ground

Standard cable Robot cable

Signal

abbreviation

(Reserved) (Reserved)

BK + BK – ENA

ENA

ENB ENB

(Reserved)

VPS

GND

F.G

Housing: XMP-18V (J.S.T. Mfg.) Contact: BXA-001T-P0.6 Retainer: XMS-09V

Encoder differential signal phase-B input Encoder differential signal phase-A input

CB-RCP2-PA * * *

CB-RCP2-PA * * *-RB

Pin No.

16 15 14

13 12 11

9 8 7 6 5 4 3 2 1

Pin No.

1 2 3 4

5 6 7 8

9 10 11

12 13 14 15 16 17 18

Signal

abbreviation

ENA ENA

ENB ENB

GND

VPS

BK +

BK –

F.G

Actuator end

CN1 pin assignments

CN1

Cable color

Standard cable

Brown Green Purple

Pink

Blue

Orange

Yellow

Red

Gray

Ground

Robot cable

Blue

White (with blue)

Yellow

White (with yellow)

White (with red)

Red

Green

Purple

White (with purple)

Ground

Reference: Cable colors and pin assignments for units shipped on or before July 31, 2004

Controller end

CN2 pin assignments

CN2

Standard cable Robot cable

CB-RCP2-PA * * *

CB-RCP2-PA * * *-RB

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Cable color

Robot cable

Light blue (red 1)

Light blue (black 1)

White (red 1)

White (black 1)

Yellow (red 1)

Yellow (black 1)

Orange (red 2)

Orange (black 2)

Ground

CN2

Standard cable

Red

Gray Brown Green

Purple

Pink

Orange

Blue

Ground

Signal

abbreviation

(Reserved) (Reserved)

BK + BK –

ENA

ENB ENB

(Reserved) (Reserved)

GND

F.G

Pin No.

16 15

14 13 12 11 10

9 8 7 6 5 4 3 2

Pin No.

1 2 3 4

5 6 7 8

9 10 11 12 13 14 15 16 17 18

Signal

abbreviation

ENA

ENB

GND

BK +

BK –

F.G

Housing: XMP-18V (J.S.T. Mfg.) Contact: BXA-001T-P0.6 Retainer: XMS-09V

Actuator end

CN1 pin assignments

CN1

Cable color

Standard cable

Brown Green Purple

Pink

Blue

Orange

Red

Gray

Ground

Robot cable

White (red 1)

White (black 1)

Yellow (red 1)

Yellow (black 1)

Orange (black 2)

Orange (red 2)

Light blue (red 1)

Light blue (black 1)

Ground

)

 [Large-capacity controller (6 A)]

 Connect the encoder extension cable to the ENC connector. Signal table for the controller-end connector (CN2)

Pin No. Signal abbreviation Description

1 F.G Shielded wire 2 - (Not used) 3 - (Not used) 4 5V Encoder power output 5 GND 6 - (Not used) 7 VPS Encoder control signal output 8 - (Reserved)

EN B

10 EN B 11

EN A 12 EN A 13 BK – Negative side of the brake power supply 14 BK + Positive side of the brake power supply 15 - (Reserved) 16 - (Reserved)

Controller end

CN2 pin assignments

Cable color

Robot cable

Purple

White (with purple)

Blue

White (with blue)

Yellow

White (with yellow)

Green

White (with red)

Red

Standard cable

Red

Gray Brown Green

Purple

Pink

Yellow

Blue

Orange

Signal

abbreviation

(Reserved) (Reserved)

(Reserved)

Ground

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Ground

Housing: XMP-18V (J.S.T. Mfg.) Contact: BXA-001T-P0.6 Retainer: XMS-09V

Encoder differential signal phase-B input

Encoder differential signal phase-A input

Standard cable Robot cable

Pin No.

Actuator end

CN1 pin assignments

Signal

abbreviation

Cable color

Standard cable

Brown Green Purple

Pink

Blue

Yellow

Orange

Red

Gray

Ground

Robot cable

Blue

White (with blue)

Yellow

White (with yellow)

White (with red

Green

Red

Purple

White (with purple)

Ground

4.5 Connecting the Communication Cable

Connect the communication cable to the SIO connector.

RS485 conversion adapter end

Cable color

Brown 5V Yellow

Red

Orange

Blue

Green

Shorting wire UL1004AWG28 (black)

Shielded, not connected

Signal

abbreviation

SGA GND SGB GND

CB-RCA-SIO * * *

Pin No.

1 2 3 4 5 6

Pin No.

1 2 3 4 5

6 7 8

Signal

abbreviation

SGA

SGB

EMGS EMGA

24V

GND

EMGB

Controller end

Cable color

Yellow

Orange

Brown/Green

Black

Red/Blue

Black

Shielded

Pin assignments of the cable-

end connector

5. I/O Signal Control and Signal Functions

5.1 PIO Patterns and Signal Assignments

Parameter No.

25 setting

0 1

Conventional This pattern is compatible with the pin assignments of the RCP controller. Standard All functions of the RCP controller are available, plus the home-return command input, servo ON input, reset input, moving output and ready output. 64-point positioning Compared with the standard pattern offering only 16 positioning points, this pattern provides up to 6 4 positioning points. However, the servo ON input, ready output and zone output have been removed. 2 zone output signals Compared with the standard pattern offering only one zone output signal, this pattern pro vides two zone output signals. However, the moving output has been removed. The boundaries for the second zone output signal are specified in parameter Nos. 23 and 24. Teaching This pattern allows for normal positioning operation, as well as jogging and writing of current position to a specified position using I/Os. Switching between the normal positioning mode and teaching mode is effect ed by the MODE input signal. The mode switching completion output has been added to indicate that the modes h ave been switched. However, the zone output has been removed. (Note) Position data can be rewritten up to around 100,000 times. 4 points (air cylinder) Use of the RCP2 as an air cylinder is assumed in this pattern. The number of positioning points is limited to four, but a direct command input and a position complete output are provided for each target position in line with the conventional practice of air cylinder control. This lets the user control the RCP2 just like an air cylinder.

Quick reference table for functions available under each PIO pattern ( --- Available, X --- Not available)

No. 25

Number of

positioning

points

Number of

zone output

signals

Home return

0 16 points 1 signal X X X X X X X 1 16 points 1 signal 2 64 points None 3 16 points 2 signals 4 16 points None

             

5 4 points 1 signal X X

For details, refer to 5.1.2, “Signal Assignment Table for Respective PIO Patterns.”

Note: The servo ON input signal (SON) is not available if the conventional, 64-point or 4-point

positioning pattern is selected.

Therefore, always set parameter No. 21 (Servo ON disable selection) to “1: [Disable]” when

the controller is used in either of these PIO patterns.

Feature of PIO pattern

Input signals Output signals

Servo ON Reset Jog Write Moving Ready

  



X X X X X X X

X X X X

5.1.1 Explanation of Signal Names

The following explains the signal names, and gives a function overview of each signal. In the explanation of operation timings provided in a later section, each signal is referenced by its selfexplanatory name for clarity. If necessary, however, such as when marker tubes are inserted as a termination of the flat cable, use the signal abbreviations.

 PIO pattern = “0: [Conventional],” “1: [Standard],” “2: [64-point positioning],” “3: [2 zone output

signals]”

Category Signal name

Input

Output

Start CSTR Movement is started at a rise edge of this signal. Command position number PC1

*Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a stop Home return HOME The actuator moves in the positive direction while this signal is ON. Servo ON SON The servo remains ON while this signal is ON.

Alarm reset RES An alarm is reset at a rise edge of this signal. Completed position number PM1

Moving MOVE This signal turns ON while the actuator is moving, and turns OFF

Position complete PEND This signal turns ON when the target position was reached and the

Home return completion HEND This signal is OFF immediately after the power is input, and turns

Zone ZONE1

Ready SRDY This signal is always output once the servo is turned ON and the

*Alarm *ALM This signal remains ON in normal conditions of use and turns OFF

*Emergency stop *EMGS This signal is enabled on a “built-in cutoff relay” controller.

Signal

abbreviation

PC2 PC4 PC8 PC16 PC32

PM2 PM4 PM8 PM16 PM32

ZONE2

Function overview

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

The servo remains OFF while this signal is OFF.

The relevant position number is output when positioning has completed. The signal will turn OFF when the next start signal is received. It is used by the PLC to check if the commanded position has definitively been reached, and also to provide a position interlock, etc.

while it is stopped. It is used for operation check and also to determine whether the load is contacted during push & hold operation.

actuator has entered the specified in-position range. It is used to determine whether positioning has completed.

ON when home return has completed. This signal is output when home return has completed and the

current actuator position is inside the range set by the applicable parameter. It can be used as a limit switch at an intermediate point or as a simple ruler during push & hold operation.

controller is ready to operate. The signal is synchronized with the lit/unlit status of the “RUN” LED on the front panel of the enclosure. It is used by the PLC to determine when it can start operation.

when an alarm generates.

OFF: Emergency stop has been actuated

 PIO pattern = “4: [Teaching]”

Category Signal name

Input

Output

Start CSTR Movement is started at a rise edge of this signal. Command position

number

*Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a

Home return HOME Home return operation is started at a rise edge of this signal. Operation mode MODE ON: Teaching mode, OFF: Normal mode Current-position write PWRT When this signal has remained ON for 20 msec or longer, the

+Jog JOG+ The actuator moves in the positive direction while this s ignal is

–Jog JOG- The actuator moves in the negative direction while this signal is

Servo ON SON The servo remains ON while this signal is ON.

Alarm reset RES An alarm is reset at a rise edge of this signal. Completed position

number

Moving MOVE This signal turns ON w hile the actuator is moving, and turns

Position complete PEND This signal turns ON when the target position was reached and

Home return completion HEND This signal is OFF immediately after the power is input, and

Current operation mode MODES Currently enabled mode (ON: Teaching mode, OFF: Normal

Write completion WEND This signal is output upon completion of writing to the nonvolatile

Ready SRDY This signal is always output once the servo is turned ON and the

*Alarm *ALM This signal remains ON in normal conditions of use and turns

*Emergency stop *EMGS This signal is enabled on a “built-in cutoff relay” controller.

Signal

abbreviation

PC1 PC2 PC4 PC8

PM1 PM2 PM4 PM8

Function overview

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

stop

current position will be stored under the position number selected by PC1 to PC8.

ON.

The servo remains OFF while this signal is OFF.

OFF while it is stopped. It is used for operation check and also to determine whether the load is contacted during push & hold operation.

the actuator has entered the specified in-position range. It is used to determine whether positioning has completed.

turns ON when home return has completed.

mode)

memory in response to a current-position write command (PWRT).

controller is ready to operate. The signal is synchronized with the lit/unlit status of the “ RUN” LED on the front panel of the enclosure. It is used by the PLC to determine when it can start operation.

OFF when an alarm generates.

OFF: Emergency stop has been actuated

 PIO pattern = “5: [4 points]

Category Signal name

Input

Rear end move ST0 The actuator starts moving to the rear end at the rise edge of the

Signal

abbreviation

Function overview

signal.

Output

Front end move ST1 The actuator starts moving to the front end at the rise edge of

Intermediate point 1 move ST2 The actuator starts moving to intermediate point 1 at the rise

Intermediate point 2 move ST3 The actuator starts moving to intermediate point 2 at the rise

*Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a

Alarm reset RES An alarm is reset at a rise edge of this signal. Rear end complete PE0 The signal turns ON when the actuator completes moving to the

Front end complete PE1 The signal turns ON when the actuator completes moving to the

Intermediate point 1 complete

Intermediate point 2 complete

Zone ZONE1 This signal is output when home return has completed and the

Position complete PEND This signal is used to determine if the controller is ready

Home return completion HEND This signal is OFF immediately after the power is input, and

PE2 The signal turns ON when the actuator completes moving to

the signal.

edge of the signal.

stop

rear end.

front end.

intermediate point 1.

intermediate point 2.

current actuator position is inside the range set by the applicable parameter. It can be used as a limit switch at an intermediate point or as a simple ruler during push & hold operation.

following the power on. The controller is ready to perform operation if an emergency stop is not actuated, motor drive power is not cut off (= the servo is on) and the pause signal is input.

turns ON when home return has completed.

*Alarm *ALM This signal remains ON in normal conditions of use and turns

OFF when an alarm generates.

*Emergency stop *EMGS This signal is enabled on a “built-in cutoff relay” controller.

OFF: Emergency stop has been actuated

5.1.2 Signal Assignment Table for Respective PIO Patterns

The same signal may be assigned to a different pin number depending on the PIO pattern. Therefo re, whe n creating a PLC sequence or wiring the signals, refer to this table to ensure each signal is assigned correctly. When “4: [Teaching]” is selected, the meaning of each pin number will vary depending on the mode. Accordingly, also pay due attention to when mode switching will occur.

Category Wire color

No.

1A +24V 2A 0V Red - 1 N

Input

3A Orange - 1 CSTR PC1 PC1 PC1 PC1 ST0 4A Yellow - 1 PC1 PC2 PC2 PC2 PC2 ST1 5A Green - 1 PC2 PC4 PC4 PC4 PC4 ST2 6A Blue - 1 PC4 PC8 PC8 PC8 PC8 ST3 7A Purple - 1 PC8 - PC16 - MODE 8A Gray - 1 - *STP PC32 *STP *STP/JOG + *STP

9A White - 1 - CSTR CSTR CSTR CSTR/PWRT 10A Black - 1 *STP HOME HOME HOME HOME 11A Brown - 2 - SON *STP SON SON 12A 13A

Lower stage

Output

3B Blue - 2 PM1 PM1 PM1 PM1 PM1 PE0

4B Purple - 2 PM2 PM2 PM2 PM2 PM2 PE1

5B Gray - 2 PM4 PM4 PM4 PM4 PM4 PE2

6B White - 2 PM8 PM8 PM8 PM8 PM8 PE3

7B Black - 2 PEND ZONE1 PM16 ZONE1 MODES ZONE1

8B Brown - 3 HEND MOVE PM32 ZONE2 MOVE -

9B Red - 3 ZONE1 PEND PEND PEND PEND/WEND PEND 10B Orange - 3 *ALM HEND HEND HEND HEND HEND 11B Yellow - 3 *EMGS 12B Green - 3 - SRDY MOVE SRDY SRDY 13B

Upper stage

Brown - 1

Red - 2 - RES RES RES RES/JOG – RES

Orange - 2 (Not used)

Yellow - 2

Green - 2 (Not used)

Blue - 3 - *ALM *ALM *ALM *ALM *ALM

0 1 2 3 4 5

Parameter No. 25 setting

P24

(Not used)

Note:

[1] The signals indicated by * in the table (*ALM, *STP and *EMGS) are based on the negative

logic, meaning that they remain ON in normal conditions of use. [2] Insulate the pins indicated “Not used” (13A, 1B and 2B) without connecting anything. [3] The NPN and PNP specifications use the same power line configuration, so there is no need to

reverse the power signal assignments for a PNP controller. [4] *EMGS (emergency-stop state) assigned to pin No. 11B is enabled on a “built-in cutoff relay”

controller.









5.2 Interface Circuit

The standard interface specification of the controller is NPN, but the PNP specification is also available as an option. To prevent confusion during wiring, the NPN and PNP specifications use the same power line configuration. Accordingly, there is no need to reverse the power signal assignments for a PNP controller.

5.2.1 External Input Specifications

Item Specification

Number of input points 10 point s

Input voltage Input current 7 mA/point

Operating voltage

Leak current 1 mA or less/point

Isolation method Photocoupler

Internal circuit configuration

[NPN specification]

External power supply

+24V

[PNP specification]

External power supply

+24V

Each input

24 VDC  10%

ON voltage: 18 V min. (3.5 mA) OFF voltage: 6 V max. (1 mA)

Controller

P24V

R = 560

R = 3.3 k

Controller

Internal circuit

R = 22 k

C = 0.1

Internal circuit

R = 22 k

C = 0.1

5.2.2 External Output Specifications

Item Specification

Number of output points 10 points

Rated load voltage 24 VDC

Maximum current 20 mA/point

Residual voltage 2 V or less Isolation method Photocoupler

Internal circuit configuration

[NPN specification]

[PNP specification]

Internal circuit

Controller

Internal circuit

Controller

Each output

P24V

Load

External power

supply

+24V

External power

supply

+24V

5.3 Details of I/O Signal Functions

An input time constant is provided for the input signals of this controller, in order to prevent malfunction due to chattering, noise, etc. Except for certain signals, switching of each input signal will be effected when the signal has been re ceived continuously for at least 6 msec. For example, when an input is switched from OFF to ON, the controller will only recognize that the input signal is ON after 6 msec. The same applies to switching of input signals from O N to OFF (Fig. 1).

Recognition by controller

5.3.1. Details of Each Input Signal

 Start (CSTR)

Upon detecting a rise (OFF  ON) edge of this signal, the controller will read the target point number as a binary code consisting of four bits from PC1 to PC8 (or six bits from PC1 to PC32 in the 64-point positioning pattern), and execute positioning to the target position of the corresponding position data. Before issuing a start command, all operation parameters such as the target po sition and speed must be set in the nonvolatile memory of the controller. If a start command is issued when home return operation has not been performed yet after the power was input (the HEND output signal is OFF), the controller will automatically perform home return operation before positioning to the target position.

 Command position number (PC1 to PC32)

When a movement command is effected upon OFF  ON of the start signal, the six-bit binary code consisting of signals PC1 to PC32 will be read as the command position number. (Only with an expanded controller the binary code consists of six bits from PC1 to PC32. The binary code for all other controller types consists of four bits from PC1 to PC8.) The weight of each bit is as follows: 2 A desired position number from 0 to 63 (maximum) can be specified.

 Pause (*STP)

When this signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. The remaining movement is retained and will be resumed when the signal is turned ON again. To abort the movement command, turn ON the alarm reset signal while this signal is OFF to cancel the remaining movement. The *STP signal can be used for the following purposes: [1] Provide a low-level safety measure to stop the axis while the servo is ON, such as a sensor that detects a

person approaching the system [2] Prevent contact with other equipment [3] Perform positioning based on sensor or LS detection (Note) If the *STP signal is input while the actuator is performing home return, the movement command will

Input signal

Not recognized

6 [msec] 6 [msec]

Fig. 1 Recognition of Input Signal

for PC1, 21 for PC2, 22 for PC4, 23 for PC8, 24 for PC16 and 25 for PC32.

be retained if the actuator is yet to contact a mechanical end. If the signal is input after the actuator has reversed upon contacting a mechanical end, home return will be performed again from the beginning.

 Home return (HOME)

The controller will start home return operation upon detection of an OFF  ON edge of this signal. When the home return is complete, the HEND signal will be output. The HOME signal can be input as many times as required. (Note) The HOME signal is not an absolute requirement, because even if home return has not yet been

performed after the power was input, the controller will automatically perform home return operation before positioning to the target position.

Setting “0.00 mm” as the position data will allow for movement to the home. Still, the HOME signal is

convenient when there is no space in the position-data table or when the controller is used in the teaching mode.

 Servo ON (SON)

The servo remains ON while this signal is ON. Use this signal if servo ON/OFF control must be performed by the PLC as part of a safety circuit covering the entire system. Parameter No. 21 that defines whether to enable or disable this signal must always be set. Set “0: [Enable]” if the SON signal is used, or “1: [Disable]” if the signal is not used. (Note) If the SON signal is turned OFF during movement in case of error, the actuator will decelerate to a stop

at the emergency-stop torque and then the servo will turn OFF.

 Alarm reset (RES)

This signal provides two functions. [1] Reset the alarm output signal (*ALM) that turned OFF due to an alarm

If an alarm has generated, turn ON this signal after confirming the nature of the alarm. The controller will reset the alarm upon detection of a rise edge of the RES signal.

(Note) Certain alarms cannot be reset by the RES signal. For details, refer to 10, “Troubleshooting.” [2] Cancel the remaining movement when the pause signal is OFF

This function is used when the remaining movement must be cancelled to allow for incremental moves (movements at a constant increment) from the position where the actuator stopped following a sensor detection.

 Operation mode (MODE)

This signal is enabled when parameter No. 25 is set to “4: [Teaching].” Turning the MODE signal ON will switch the normal operation mode to the teaching mode. (Note) For the mode switching to occur, all of the *STP, CSTR and RES input signals must be OFF.

Once the mode switches, the MODES output signal will turn ON. Configure the system in such a way that the PLC will accept a PWRT, JOG+ or JOG- operation command after confirming the ON status of the MODES output signal. Turn the MODE signal OFF to return to the normal operation mode. Configure the system in such a way that the PLC will accept a command in the normal operation mode

(Note) The normal operation mode cannot be restored unless all of the PWRT, JOG+ and JOG- input signals

after confirming the OFF status of the MODES output signal.

are OFF.

 Current-position write (PWRT)

This signal is enabled when the aforementioned MODES output signal is ON. If the PWRT signal has remained ON for 20 msec or longer, the controller will read the position number specified by the currently detected binary code consisting of PC1 to PC8, and write the current position data as the target position in the corresponding position data. If data other than the target position (speed, acceleration/deceleration, positioning band, etc.) are yet to be defined, the default parameter settings will be written. When the writing completes successfully, the WEND output signal will turn ON. Configure the system in such a way that the PLC will turn OFF the PWRT signal when WEND turns ON. The controller will turn OFF WEND once the PWRT signal turns OFF. (Note) An alarm will generate if a write command is issued when home return has not been performed yet or

while the actuator is moving.  Condition for PWRT to be enabled when the servo is ON:

The PWRT signal is enabled when both the JOG+ and JOG- input signals are OFF, HEND output signal is ON and MOVE output signal is OFF.

 Condition for PWRT to be enabled when the servo is OFF: The PWRT signal is enabled when the HEND output signal is ON, but whether the actuator is being moved by hand or stopped cannot be determined from HEND alone. Input the PWRT signal when the operation is stopped.

 Jog (JOG+, JOG-)

These signals are enabled when the aforementioned MODES output signal is ON. The controller will move the actuator to the +/- soft limit upon detection of a rise (OFF  ON) edge of each JOG signal. When the soft limit is reached, the actuator will be forced to decelerate to a stop without generating an alarm. The speed and acceleration/deceleration set in parameter No. 26 (PIO jog speed) and No. 9 (Default acceleration/deceleration) will be used. The actuator will not move if both the JOG+ and JOG- signals are turned ON. If both signals are turned ON while the actuator is moving, the actuator will decelerate to a stop. The controller will decelerate the actuator to a stop upon detection of a fall (ON  OFF) edge of each JOG signal. (Note) Executing jogging before home return is completed may disable the soft limits and cause the actuator

to crash into a mechanical end, so exercise due caution.

 Movement to each position (ST0 to ST3)

The number of positioning points is limited to four, so the RCP2 can be controlled just like an air cylinder. When the OFF  ON rise edge of each movement signal is detected, the actuator will move to the target position corresponding to the applicable position data. Before executing a command using any of these signals, make sure the target position, speed and other operation data are set in the position table using a PC or teaching pendant.

Rear end move (ST0) 0 Set the rear end position in position No. 0. Front end move (ST1) 1 Set the front end position in position No. 1. Intermediate point 1 move (ST2) 2 Set the position of intermediate point 1 in position No. 2. Intermediate point 2 move (ST3) 3 Set the position of intermediate point 2 in position No. 3.

If a movement command is issued when the first home return is not yet completed after the power was input, home return will be performed automatically to establish the coordinates first, after which the actuator will move to the target position.

Corresponding

position number

Remarks

5.3.2 Details of Each Output Signal

 Completed position number (PM1 to PM32)

These signals can be used to check the completed position number when the PEND signal turns ON. The signals are output as a binary code. Immediately after the power is input, all of the PM1 to PM32 signals are OFF. (Only with an expanded controller the binary code consists of six bits from PM1 to PM32. The binary code for all other controller types consists of four bits from PM1 to PM8.) All of PM1 to PM32 are OFF also when the actuator is moving. As described above, this signal is output only when positioning is completed. (Note) All of PM1 to PM32 will turn OFF when the servo is turned OFF or an emergency stop is actuated.

They will return to the ON status when the servo is turned ON again, provided that the current position is inside the in-position range with respect to the target position. If the current position is outside the range, the signals will remain OFF.

When the power is input, the PEND signal will turn ON. Since PM1 to PM32 are all OFF, this condition

is the same as one achieved after positioning to position “0” is completed.

Check the position of position 0 after the movement command has completed. If an alarm is present, the corresponding alarm code (abbreviated form) consisting of four bits from PM1 to PM8

will be output. The meanings of these signals vary between the normal condition and the alarm condition, so be careful not to use them wrongly in the sequence.

 Moving (MOVE)

This signal is output while the servo is ON and the actuator is moving (also during home return, push & hold operation or jogging). Use the MOVE signal together with the PEND signal to allow the PLC to determine the actuator status. The MOVE signal will turn OFF after positioning or home return is completed or a judgment is made during push & hold operation that the load is being contacted.

 Position complete (PEND)

This signal indicates that the target position was reached and positioning has completed. Use the PEND signal together with the MOVE signal to allow the PLC to determine the positioning status. When the controller becomes ready after the power was input and the servo has turn ed ON, this signal will turn ON if the position deviation is within the in-position range. Then, when a movement command is issued by turning ON the start signal, the PEND signal will turn OFF. It will turn ON again when the deviation from the target position falls within the in-position range. Once turned ON, the PEND signal will not turn OFF even when the position deviation subsequently exceeds the in-position range. (Note) If the start signal remains ON, the PEND signal will not turn OFF even when the deviation from the

target position falls within the in-position range: it will turn ON when the start signal turns OFF.

Even when the motor is stopped, the PEND signal will remain OFF if the pause signal is input or the

servo is OFF.

 Home return completion (HEND)

This signal is OFF immediately after the power is input, and turns ON in either of the following two conditions: [1] Home return operation has completed with respect to the first movement command issued with the start

signal. [2] Home return operation has completed following an input of the home return signal.

Once turned ON, the HEND signal will not turn OFF unless the input power supply is cut off, a soft reset is executed, or the home return signal is input again.

The HEND signal can be used for the following purposes: [1] Check prior to establishing the home if movement toward the home direction is permitted, in cases where an

obstacle is located in the direction of the home [2] Use as a condition for writing the current position in the teaching mode [3] Use as a condition for enabling the zone output signal

 Zone (ZONE1, ZONE2)

Use a ZONE signal as a limit switch at an intermediate point or as a simple ruler. The ZONE1 signal will turn ON when the current position is inside the range specified by parameter No s. 1 and 2, and turn OFF if the current position is outside this range. (If the 2 zone output signals pattern is selected, the ZONE2 signal will turn ON/OFF in the same manner with respect to the range specified by parameter Nos. 23 and 24.) (Note) The ZONE signals are enabled after the coordinate system is established following a completion of

home return. They will not be output simply by turning on the power.

As long as home return has completed, the ZONE signals remain enabled while the se rvo is OFF or

during an emergency stop.

 Current operation mode (MODES)

This signal is enabled when the teaching pattern is selected. The MODES signal will turn ON when the teaching mode is enabled upon selection of the teaching mode via the operation mode input signal (MODE signal ON). Thereafter, the MODES signal will remain ON until the MODE signal turns OFF. Configure the system in such a way that the PLC will start teaching operation after confirming that the MODES signal has turned ON.

 Write completion (WEND)

This signal is enabled only when the teaching pattern is selected. The WEND signal is OFF immediately after the controller has switched to the teaching mode. It will turn ON when the writing of position data in response to the current-position write signal is completed. When the current-position write signal turns OFF, this signal will also turn OFF. Configure the system in such a way that the PLC will acknowledge completion of writing when the WEND signal turns OFF.

 Completion of each position (PE0 to PE3)

The number of positioning points is limited to four, so the RCP2 can be controlled just like an air cylinder. These signals indicate that the target position corresponding to each movement command (ST0, ST1, ST2 or ST3) has been reached, in the same way the reed switch signal does for an air cylinder.

Output signal Meaning of the signal Rear end complete (PE0)

Front end complete (PE1) Intermediate point 1

complete (PE2) Intermediate point 2 complete (PE3)

(Note) These signals turn OFF when the servo is turned OFF or an emergency stop is actuated. They will

return to the ON status when the servo is turned ON again, provided that the current position is inside the in-position range with respect to the target position. If the current position is outside the range, the signals will remain OFF.

The actuator has reached and stopped at the rear end (target position set in position No. 0). The actuator has reached and stopped at the front end (target position set in position No. 1). The actuator has reached and stopped at intermediate point 1 (target position set in position No. 2). The actuator has reached and stopped at intermediate point 2 (target position set in position No. 3).

 Ready (SRDY)

This is a monitor signal indicating that the servo is ON and the motor is ready. The ON/OFF status of the SRDY signal is synchronized with the lit/unlit status of the “RUN” LED on the front panel of the enclosure. Use this signal as a condition for starting a movement command on the PLC side. Refer to 7.1, “How to Start,” for the timing to issue this signal after the power is input.

 Alarm (*ALM)

This signal remains ON while the controller is operating properly, and turns OFF whe n an alarm has generated. Provide an appropriate safety measure for the entire system by allowing the PLC to monitor the OFF status of this signal. For details of alarms, refer to 10, “Troubleshooting.”

 Emergency stop (*EMGS)

This signal is enabled on a “built-in cutoff relay” controller. The *EMGS signal remains ON in normal conditions of use, and turns OFF when the eme rge ncy-stop switch has been pressed. Provide an appropriate safety measure for the entire system by allowing the PLC to monitor the OFF status of this signal.

(Reference) Output Signal Changes in Each Mode

Mode classification MOVE PEND SRDY HEND PM1-PM8 Actuator is stopped with the servo ON after the power was

input Home return is in progress following an input of the home return signal Home return has completed following an input of the home return signal

Actuator is moving in the positioning/push & hold mode ON OFF ON ON OFF

OFF ON ON OFF OFF

ON OFF ON OFF OFF

OFF ON ON ON OFF

Actuator is paused in the positioning/push & hold mode OFF OFF ON ON OFF Positioning has completed in the positioning mode OFF ON ON ON ON

Actuator has stopped after contacting the load in the push & hold mode Actuator has stopped after missing the load (no load) in the push & hold mode

Actuator is stopped with the servo ON in the teaching mode OFF ON ON Actuator is jogging in the teaching mode ON ON ON

Actuator is being moved by hand with the servo OFF in the teaching mode

Servo is OFF after home return OFF OFF OFF ON OFF Emergency stop has been actuated after home return OFF OFF OFF ON

OFF ON ON ON ON OFF OFF ON ON ON

OFF

OFF ON

(Note) Determine whether the actuator has stopped after contacting the load or missing the load from the

signal statuses of MOVE, PEND and PM1 to PM8.

6. Data Entry <Basics>

This controller doesn’t use command words, so there is no need to create a program. All you need is to enter the target position in the position-data table, and the actuator will move to the specified position. Position data consists of number (No.), target position (Position), speed (Speed), acceleration/deceleration (ACC), push (Push), positioning band (Pos. band), and acceleration only MAX (ACC MAX). The description in parentheses is as displayed on the teaching pendant. The target position can be specified in two different modes: by absolute coordinate specification (absolute mode) in which the distance from the home is entered, or by relative coordinate specification (incremental mode) in which the incremental movement from the current position is entered.

Position-data table

No.

Position Note

Speed

Acceleration/

deceleration

Push

0 0 100 0.3 0 0.1 0 1 30 100 0.3 0 0.1 0 2 10 100 0.3 0 0.1 0

      

~ ~

 

100

 

100

 

0.3

 

When data is entered in the position column of the position-data table, the default values will be automatically entered in the remaining columns. Change the default values as necessary. To change a default value, change the corresponding parameters starting with “Default.” The default values vary depending on the actuator type.

This indicates that the incremental mode is active. (This symbol is displayed only on the teaching pendant. Separate columns for incremental specification are provided in the PC software.)

Note: Enter position data first. Any attempt to enter other data before position data will be rejected. You can enter position data containing two decimal places. However, the controller only recognizes position data as a multiple of its minimum resolution. The minimum resolution of the controller varies depending on the actuator lead. For the above reason, the second decimal place in the entered position data may be rewritten

in accordance with the actuator lead.

Example: Entered value Stored value

50.01 50.03



Positioning

band

 

0.1

Acceleration

only MAX

 

~ ~

6.1 Description of Position-Dat a Table

(1) No.

(2) Target position

(Position)

(3) Speed (Speed)

(4) Acceleration/ deceleration (ACC)

Note: Enter appropriate speed and acceleration/deceleration by referring to Appendix, “List of

Supported Actuator Specifications” and by also considering the installation condition and shape of load, so as to prevent the actuator from receiving excessive impact or vibration.

If you want to raise the speed or acceleration/deceleration, the payload and the characteristics

of your specific actuator model must be considered. Contact IAI’s Sales Engineering Section for the maximum speed and acceleration/deceleration that can be entered for your specific application.

 Indicate the position data number.

To enter an incremental movement, press the minus key in this column. On the teaching pendant, a “=” will be displayed between the number and position columns. The minus key need not be pressed in the absolute mode.

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

Absolute mode: Enter the distance to the target actuator position from

the home.

Incremental mode: Enter the distance to the target actuator position from

the current position. A negative value can also be entered (for movement in the negative direction along the displayed coordinate axis).

No. Position

0 30 Absolute mode 30 mm from the home

1 2 3 100 Absolute mode 100 mm from the home

10 Incremental mode +10 mm from the current position

-10 Incremental mode -10 mm from the current position

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

The default value varies depending on the actuator type.

 Enter the acceleration/deceleration at which the actuator will be moved,

in [G]. Basically, the acceleration should conform to the rating specified in the catalog. With this product, the acceleration can be raised to reduce the tact time, provided that the “actual payload is significantly smaller than the rated load capacity.” For this reason, the acceleration field in the position table permits entry of values greater than the rated acceleration.

Speed

Acceleration/deceleration (ACC)

Start Completion Time

Acceleration/deceleration G --- MIN 0.01 G (Slow rise) MAX 0.9 G (Quick rise) (Varies depending on the model.)

(5) Push (Push)

 Select the positioning mode or push & hold mode.

The default value is “0.” 0: Positioning mode (= Normal operation) Other than 0: Push & hold mode [%]

 In the push & hold mode, enter the current-limiting value for the pulse

motor during push & hold operation.

Be sure to refer to 6.1.1, “Relationship of Push Force at Standstill and Current-Limiting Value” that specifies the relationship of the push force to be applied to the load at standstill [kgf] on one hand, and the current-limiting value on the other, for each actuator type.

Note: If the push force is too small, a false detection of push & hold condition may occur due to slide

resistance, etc., so exercise caution.

(6) Positioning band (Pos. band)

 The function of the positioning band varies depending on whether the

push & hold setting in (5) is “0” or “other than 0.”

(A) Push = 0 (Positioning mode)

 In the positioning mode, enter the position-complete detection width

(distance to the target position), in [mm].

 The distance to the target position indicates the range prior to the target

position, upon entry of the actuator in which range a position complete signal will be output.

The default value is “0.1 [mm]” (Fig. A).

(B) Push = Other than 0 (Push & hold mode)

 Enter the maximum push amount (distance from the target) in the push

& hold mode, in [mm] (Fig. B).

 If the push direction corresponds to the negative direction along the

displayed coordinate axis, add a – (minus) sign to the entered value.

[A] Push = 0

Distance to the position set in (2)

Speed

Moving distance

(6) Positioning band (6) Positioning band

Fig. A Fig. B

[B] Push = Other than 0

Distance to the position set in (2)

Speed

Moving distance

(7) Acceleration only MAX

(ACC MAX)

(7) Acceleration only MAX = 0 (7) Acceleration only MAX = 1

Speed

Acceleration/deceleration

set in (4)

 Select the specified acceleration or maximum acceleration by entering

“0” or “1.”

The default value is “0.”

0: Specified acceleration --- The value entered in (4) becomes the

actual acceleration/deceleration.

1: Maximum acceleration --- The maximum acceleration.

The deceleration conforms to the value entered in (4).

Moving distance

Maximum acceleration

Speed

Acceleration/deceleration set in (4)

Moving distance

Note: Enable the acceleration only MAX setting when the actual payload is no more than one-third

the rated load capacity.

Check the rated load capacity by referring to Appendix, “List of Supported Actuator

Specifications.”

6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value

When performing operation in the push & hold mode, enter the current-limiting value (%) in the push column of the position-data table. Determine the current-limiting value (%) from the push force to be applied to the load at standstill. The graphs below illustrate the relationship of push force at standstill and current-limiting value for each actu ator type:

 Slider type (1) SA5/SA6/SS type (2) SA7 type

Push force (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

Push force (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

Push force (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

Low-speed type Low-speed type

(Lead: 3 mm) (Lead: 4 mm)

Push force (N)

Medium-speed type Medium-speed type

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

Push force (N)

High-speed type High-speed type

(Lead: 12 mm) (Lead: 16 mm)

Push force (N)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

(3) SM type

Push force (N)

Low-speed type

(Lead: 5 mm)

Current-limiting value (ratio in %)

Medium-speed type

(Lead: 10 mm)

Current-limiting value (ratio in %)

High-speed type

(Lead: 20 mm)

Current-limiting value (ratio in %)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

 Rod type (1) RPA type (2) RXA type

Push force (N)

Current-limiting value (%)

Push force (N)

Current-limiting value (%)

Low-speed type

(Lead: 2.5 mm)

Medium-speed type

(Lead: 5 mm)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

(3) RSA/RSW type (4) RMA/RMW type

Push force (N)

Low-speed type Low-speed type

(Lead: 2.5 mm) (Lead: 4 mm)

Push force (N)

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

Medium-speed type Medium-speed type

(Lead: 5 mm) (Lead: 8 mm)

Push force (N)

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

High-speed type High-speed type

(Lead: 10 mm) (Lead: 16 mm)

Push force (N)

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

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

(5) RFA/RFW type

Push force (N)

Push force (N) Push force (N)

Current-limiting value (%)

Low-speed type

(Lead: 2.5 mm)

Medium-speed type

(Lead: 5 mm)

High-speed type

(Lead: 10 mm)

Current-limiting value (%)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for

reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.

The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

6.2 Explanation of Modes

6.2.1 Positioning Mode Push = 0

Speed

Moving distance

6.2.2 Push & Hold Mode Push = Other than 0

(1) Load was contacted successfully

Speed

Moving distance

The actuator continues to push the load at the push force at standstill determined by the

Warning

The push speed is set as follows in accordance with the speed set in the position-data table:

Push speed 20 mm/sec Set speed

current-limiting value. Since the actuator is not inactive, exercise due caution when handling the machine in this condition.

Position complete signal Completed position number

Positioning band

Output

Positioning band

Output

20 mm/sec or more Less than 20 mm/sec

(1) The position complete output will turn

ON at a position preceding the target position by the positioning band. A completed position number signal will be output at the same time.

(1) After reaching the target position, the actuator

will move at low speed.

When the Pos. band set in the data table (see

Note) is reached after the actuator contacts the load and the stepper motor current has reached the current-limiting value, the position complete output will turn ON. A completed position number signal will be output at the same time.

Note: Set the parameter “Push & hold stop

judgment period.” The default value of “255 [msec]” is already entered.

The actuator is holding the load in position while

pushing it.

Set speed

(2) Load was not contacted (missed)

Completed position number

Speed

Moving distance

Positioning band

Output

(3) Load moves during push & hold operation

(a) Load moves in the pushed direction

Position complete signal Completed position number

Speed

Moving distance

(b) Load moves in the opposite direction (Actuator is pushed back by the reactive force of the load)

Position complete signal Completed position number

Speed

Moving distance

Output

Positioning band

Output

(1) After reaching the target position, the actuator

will move at low speed.

Even after contacting the load, the actuator will

move to the end of the positioning band if the stepper motor current is yet to reach the current-limiting value.

The position complete output will not turn ON

even when the end of the positioning band is reached. In this case, only the completed position number will be output. (Provide a timeout check process after a sufficient period with a PLC.)

If the load moves in the pushed direction after

the position complete output has turned ON, the actuator will push the load within the positioning band.

If the current drops below the limiting value,

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

If the actuator is pushed back after the position

complete output has turned ON because the actuator thrust is smaller than the reactive force of the load, the actuator will be pushed back all the way until its thrust balances out with the reactive force of the load. The position complete output will remain ON and the completed position number will be output continuously.

(4) Positioning band was entered with a wrong sign

If the positioning band is entered with a wrong

Speed

sign, the position will deviate by twice the positioning band, as shown to the left, so exercise due caution.

Moving distance

Positioning

band

Positioning

band

6.2.3 Speed Change during Movement

Speed control involving multiple speed levels is possible in a single operation. The actuator speed can be decreased or increased at a certain point during movement. However, the position at which to implement each speed change must be set.

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

6.2.4 Operation at Different Acceleration and Deceleration Settings

The actuator will accelerate and decelerate at different speeds if “1” is entered under “Accelerat ion only MAX” in the position data. The acceleration conforms to the maximum acceleration. The deceleration conforms to the value entered under “Acceleration/deceleration” in the position data.

Maximum acceleration Deceleration can be set freely

Note: Although the maximum acceleration varies depending on the actuator, the limit is three times Therefore, enable the acceleration only MAX function only when the payload is no more than

Enabling this function when the payload is equivalent to the rated load capacity may generate Even when an overload error does not generate, the actuator may still receive an excessive

Check the rated load capacity by referring to Appendix, “List of Supported Actuator

Speed

Time

the rated acceleration. one-third the rated load capacity and you want to stop the actuator along a gradual

deceleration curve. an overload error. impact load that shortens the life of the actuator. Therefore, exercise due caution when

enabling the acceleration only MAX function. Specifications.”

6.2.5 Pause

The actuator can be paused during movement using an external in put signal (*pause). The pause signal uses the contact B logic (always ON) to ensure safety. Turning OFF the *pause input will cause the actuator to decelerate to a stop, while turning it ON will allow the actuator to complete the remaining operation.

*Pause signal

Actuator operation

(Note) During deceleration, the acceleration/deceleration set in the position table under the currently executed

position number is used.

The remaining movement of the actuator can be cancelled by turning ON the reset input during pause (the movement will be cancelled upon rise of the reset input signal).

*Pause signal

Reset

Actuator operation

Note) If parameter No. 25 (IO pattern) is set to “0: [Conventional],” the reset input is not available.

ON ON

OFF

Target position

6.2.6 Zone Signal Output

A signal will be output when the actuator enters the specified zone. The zone signal will turn ON when the actuator enters the zone predefined by the applicable parameters. (The zone can be set arbitrarily.)

If parameter No. 25 is set to “3: [2 zone output signals],” two zone output signals can be set. The second zone value is set by parameter No. 23 (Zone 2+) and No. 24 (Zone 2-). Note) The zone signal output function is not available if parameter No. 25 (PIO pattern) is set to “2: [64-point

Actuator operation

positioning]” or “4: [Teaching].”

Zone signal

Zone signal setting range

6.2.7 Home Return

(1) On the standard controller, home return must be executed after the power is turned on to establish the

home.

(2) On the absolute controller, home return is not required when the power is turned on. This is because once

home return is executed, the current position will be retained even after the power is turned off.

On the absolute controller, home return is required only after the controller is started for the first time or

when the current position has been lost due to low battery voltage, etc.

There are two ways to execute home return.  Not using the dedicated input [PIO pattern = 0 (Conventional) or 5 (4 points)]

If home return has not been executed yet, inputting a command position followed by the start signal will execute home return.

 Using the dedicated input [PIO pattern = Other than 0 (Conventional) or 5 (4 points)]

Inputting the home return signal (HOME) will execute home return regardless of whether the home position has already been established or nor.

 For details, refer to 7.2, “How to Execute Home Return.”

6.2.8 Teaching Mode (Jogging/Teaching Using PIO)

The actuator can be jogged using PIO if parameter No. 25 (PIO pattern) is set to “4: [Teaching].” The current actuator position can also be read into the controller’s position-data table using PIO. Switching between the normal positioning mode (including the push & hold mode) and the teac hing mode is implemented by turning ON/OFF the operation mode input. Among the PIO signals, the +jog and *pause inputs, –jog and reset inputs, current-position write and start inputs, and write completion and position complete outputs use the same terminal, respectively, and are toggled in accordance with ON/OFF of the operation mode input.

Operation mode input ON OFF

Mode Teaching mode Positioning mode

+Jog input *Pause input

PIO

Current-position write input Start input

Among the PIO signals, use the +jog/–jog inputs to move the actuator, and use the current-position write input to write the current actuator position to the position-data table. When the writing is complete, the write completion output will turn ON.

 For details, refer to 7.12, “Jogging/Teaching Using PIO.”

–Jog input Reset input

Write completion output Position complete output

Note: Be sure to enable the pause signal using parameter No. 15 (by setting the parameter to “0”)

(the pause signal is enabled at the factory). The system cannot switch to the teaching mode if the pause signal is disabled (i.e., the above parameter is set to “1”).

6.2.9 Overview of the “4 Points” (Air Cylinder) Mode

This mode provides a control method adjusted to that of an air cylinder by assuming that the RCP2 is used as an air cylinder. The key differences between the RCP2 and an air cylinder are summarized below. Perform proper control by referring to this table.

Item Air cylinder RCP2

Drive method Air pressure supplied via

electromagnetic valve

control Target position

Mechanical stopper

(including shock absorber) setting

Target position detection

An external detection

sensor, such as a reed

switch, is installed. Speed setting Adjusted by a speed

controller.

Acceleration/ deceleration setting

Determined in accordance

with the load, supplied air

volume, as well as the

performance of the speed

controller and

electromagnetic valve.

Position check upon power ON

Determined by an external

detection sensor, such as

a reed switch.

Ball screw/timing belt driven by a motor

Desired coordinates are entered in the [Target position] field of the position table. The coordinates can be typed in from the number keys on the PC keyboard or on the teaching pendant, or set directly by moving the actuator to the target position. Determined based on the internal coordinates provided by the position information from the position detector (encoder). Accordingly, external detection sensor is not required. A desired feed speed is entered in the [Speed] field of the position table (unit: mm/sec). Note that the rated speed is automatically set as the initial value. A desired acceleration/deceleration is entered in the [Acceleration/deceleration] field of the position table (unit:

0.01 G). (Reference) 1 G = Gravitational acceleration Note that the rated acceleration/deceleration is automatically set as the initial value. Since the acceleration/deceleration can be set in fine steps, a gradual acceleration/deceleration curve can be programmed. Immediately after the power is turned on, the controller cannot identify the current position because the mechanical coordinates have been lost. Therefore, when the first movement command is issued after the power has been input, the controller will automatically perform home return before moving the actuator to the target position.

[1]

[2]

[3]

Home position

Target position

Power is turned on here.

[1] The actuator moves at the home return speed toward the

mechanical end on the motor side.

[2] The actuator hits the mechanical end and turns back, and

then stops temporarily at the home position.

[3] The actuator moves to the target position at the speed

specified in the [Speed] field of the position table.

(Note) Pay attention not to allow any obstacle in the travel

path of the actuator during home return.

The relationships of movement command inputs/position complete outputs and corresponding position numbers are shown below. For easier identification, each input/output signal has a name similar to the naming convention used with air cylinders. However, note that the target position is determined by the value set in the [Target position] field under each position number. Therefore, changing the magnitude correlation of the settings in Nos. 0 to 3 will ch ange the meanings of the corresponding input/output signals. Accordingly, the settings in the respective position numbers should match the semantic meani ngs of the corresponding signal names used in this operation manual, unless doing so will pose a problem.

Input signal Output signal Target position

Rear end move (ST0) Rear end complete (PE0)

Front end move (ST1) Front end complete (PE1)

Intermediate point 1 move (ST2) Intermediate point 1 complete (PE2)

Intermediate point 2 move (ST3) Intermediate point 2 complete (PE3)

Setting in the [Target position] field under position No. 0 Example: 5 mm

Setting in the [Target position] field under position No. 1 Example: 390 mm

Setting in the [Target position] field under position No. 2 Example: 100 mm

Setting in the [Target position] field under position No. 3 Example: 250 mm

 Positioning relationship on the ROBO Cylinder

An example of a slider type with a stroke of 400 mm is explained.

[Motor side] [Counter-motor side]

Home position (0 mm)

Rear end complete (5 mm)

Intermediate point 2 complete (250 mm)

Intermediate point 1 complete (100 mm)

Front end complete (390 mm)

 Position table (Enter in the fields indicated in bold)

No. Position Speed

Acceleration/

deceleration

Push

0 5 500 0.3 0 0.1 0 1 390 500 0.3 0 0.1 0 2 100 500 0.3 0 0.1 0 3 250 500 0.3 0 0.1 0

Positioning

band

Acceleration

only MAX

6.3 Notes on the ROBO Gripper

(1) Finger operation

[1] Definition of position

With the two-finger type, the stroke in the specification represents the sum of travels of both fingers. Therefore, the travel of one finger is one-half the stroke. The position is specified as a travel of one finger from the home toward the closing side. Accordingly, the maximum command value is 5 mm for the GRS type and 7 mm for the GRM type.

[2] Definition of speed and acceleration

The command value applies to each finger. With the two-finger type, therefore, the relative speed and acceleration are twice their respective command values.

[3] Operation mode in gripper applications

When the actuator is used to grip the load, be sure to select the “push & hold mode.” (Note) In the “positioning mode,” a servo error may occur while the load is gripped.

[Diagrams of gripping force and current-limiting value]

Gripping force (N)

Current-limiting value (ratio in %)

Gripping force (N)

Current-limiting value (ratio in %)

Gripping force (N)

Current-limiting value (ratio in %)

Gripping force (N)

Current-limiting value (ratio in %)

Gripping force (N)

Current-limiting value (ratio in %)

Gripping force (N)

Current-limiting value (ratio in %)

(2) Removing the gripped load This gripper is designed to maintain the load-gripping force via a self-lock mechanism even when the se rvo

is turned OFF or the controller power is cut off.

If the gripped load must be removed while the power is cut off, do so by turning the open/close screw or

removing the finger attachment on one side.

[Two-finger type] Turn the open/close screw or remove the finger attachment on one side.

Open/close screw

Turn the screw counterclockwise usin

a flathead screwdriver.

Finger attachment

Opening

direction

Affixing bolt

[Three-finger type] Remove one finger attachment.

Finger attachment

Affixing bolt

7. Operation <Practical Steps>

7.1 How to Start

7.1.1 Standard Specification

(1) Connect the motor cable and encoder cable to the controller. (2) Connect the host PLC to the PIO connector using the supplied flat cable. (3) If two or more axes are connected, set the necessary items using the address switch. For details, refer to 9,

“Controlling Multiple Controllers via Serial Communication.” (4) Actuate an emergency stop or cut off the motor power. (5) Supply 24 VDC to the controller’s terminal block. (6) Confirm that the slider or rod is not contacting the mechanical end. If the slider or rod is contacting the mechanical end, or when the slider/rod is not contacting the mechanical

end but is located near the home, move the slider/rod away from the home. If the actuator is equipped with a brake, move the slider/rod after turning ON the brake release switch to

forcibly release the brake. At this time, exercise caution not to allow the load to drop suddenly due to its

own weight. Your hand may be caught by the dropped load or the robot hand or load itself may be damaged. If the screw lead is short and the actuator cannot be moved by hands, change the setting of parameter No.

28, “Direction of excitation phase signal detection” to the direction opposite to the mechanical end.

If the servo is turned ON while the slider/rod is contacting the mechanical end, excitation

Warning

(7) Connect a PC or teaching pendant and set the following parameters as the minimum initial settings:

 Parameter No. 15, “Pause input disable selection”  Parameter No. 21, “Servo ON input disable selection”  Parameter No. 25, “PIO pattern selection”

 Parameter No. 27, “Movement command type” (when “4 points” is selected)

For details, refer to 8, “Parameters.”

(8) Cancel the emergency stop or supply the motor power.

 The ALM lamp will turn off. (9) Input a pause signal (*STP) and a servo ON signal (SON) from the PLC (if these signals are enabled).

 The controller servo will turn ON and the RUN lamp (LED) will illuminate.

The position complete output (PEND) and ready output (SRDY) will also turn ON.

 If the ALM lamp is lit, there is an error. Refer to the alarm table and take an appropriate action. (10) Perform home return.

 Overview of operation on the teaching pendant

 On the RCA-T, select the “Edit/Teach” screen, bring the cursor to “*Home” in the sub display area,  On the RCA-E, select the “Teach/Play” screen, scroll until “*Home Return” is displayed, and then  On the RCB-J, the “Operation Key  Home Return” screen will be displayed automatically. Press the

phase detection may not be performed correctly and an abnormal operation or excitation detection error may result.

and then press the Return key. press the Return key. Operation key on this screen.

Overview of operation on the PC software



Select an applicable position data in the main window, and then click the [Home] button.

For details, refer to the operation manual for the teaching pendant or PC software.

 Issuing a command from the PLC

Perform signal processing appropriate for the selected PIO pattern by referring to 7.2.1, “Standard

Specification.”

Issue a command after confirming that the position complete signal (PEND) has

turned ON.

If home return cannot be performed, confirm that the *pause signal and servo ON signal are ON and that

the safety circuit is released, and also check if any error message is displayed. (11) Set the target position, speed, acceleration/deceleration, positioning band and other data in the position

table. For details on how to set these data, refer to the operation manual for the teaching pendant/PC

software. Now, automatic operation can be performed via PLC link. Timing chart at startup

Safety circuit condition

24-VDC power ON

*Pause input

Servo ON input

Ready output

Position complete output

Home return completion output

Home return operation

ALM lamp

(STP)

(SON)

RUN lamp

(SRDY)

(PEND)

(HEND)

Emergency stop is actuated or motor drive power is cut off

Initial parameter settings

Emergency stop is not actuated or motor drive power is supplied

Pause is cancell e d

Lit

Home position

Mechanical end

Start of movement

Creation of position table using the teaching pendant or PC operation

Note: If parameter No. 25 (PIO pattern) i s set to “0: [Conventional],” “2: [64-point positi oning]”

or “5: [4 points],” the servo ON input and ready output are not provided.

7.1.2 Absolute Specification (Absolute Reset)

(1) Connect the motor cable and encoder cable to the controller. (2) Connect the host PLC to the PIO connector using the supplied flat cable. (3) If two or more axes are connected, set the address of each axis using the address switch. For details, refer

to 9, “Controlling Multiple Controllers via Serial Communication.” (4) Actuate an emergency stop or cut off the motor drive power. (5) Connect the battery connector. (6) Supply 24 VDC to the controller’s terminal block.

 The alarm output signal (*ALM) will turn OFF, the alarm code output signals (PM8 to PM1) will indicate

“1101,” and the ALM lamp will illuminate. The message “Absolute encoder error (2)” will be displayed on the PC/teaching pendant, if connected. Also, a pause signal (*STP) is input from the PLC (if this signal is enabled).

(7) Confirm that the slider or rod is not contacting the mechanical end. If the slider or rod is contacting the mechanical end, or when the slider/rod is not contacting the mechanical

end but is located near the home, move the slider/rod away from the home.

If the actuator is equipped with a brake, move the slider/rod after turning ON the brake release switch to

forcibly release the brake. At this time, exercise caution not to allow the load to drop suddenly due to its own weight. Your hand may be caught by the dropped load or the robot hand or load itself may be damaged.

If the screw lead is short and the actuator cannot be moved by hands, change the setting of parameter No.

28, “Direction of excitation phase signal detection” to the direction opposite to the mechanical end.

If the servo is turned ON while the slider/rod is contacting the mechanical end, excitation

Warning

(8) Connect a PC or teaching pendant and set the following parameters as the minimum initial settings:

 Parameter No. 15, “Pause input disable selection”  Parameter No. 21, “Servo ON input disable selection”  Parameter No. 25, “PIO pattern selection”  Parameter No. 27, “Movement command type” (when “4 points” is selected)

For details, refer to 8, “Parameters.”

(9) Reset the alarm.

 Using the teaching pendant

• On the RCA-T/RCA-E, press the BEGIN/END key.

• On the RCB-J, press the Stop key.

 Using the PC software

Select an applicable position data in the main window, and then click the [Alarm] button.

 Issuing a command from the PLC

• If the PIO pattern is set to “0: [Conventional],” input a start signal (CSTR) for 6 msec or longer.

• If the PIO pattern is set to a value other than “0: [Conventional],” input a reset signal (RES) for 6 msec or longer.

 The message “Absolute encoder error (2)” will be cleared. The alarm output signal (*ALM) will turn ON and the alarm code output signals (PM8 to PM1) will turn

OFF.

phase detection may not be performed correctly and an abnormal operation or excitation detection error may result.

(10) Cancel the emergency stop or supply the motor drive power.

 The ALM lamp will turn off.

(11) Input a servo ON signal (SON) from the PLC (if these signals are enabled).

 The controller servo will turn ON and the RUN lamp (LED) will illuminate. The position complete output

(PEND) and ready output (SRDY) will also turn ON.

 If the ALM lamp is lit, there is an error. Refer to the alarm table and take an appropriate action.

(12) Perform home return.

 Overview of operation on the teaching pendant

• On the RCA-T, select the “Edit/Teach” screen, bring the cursor to “*Home” in the sub display area,

and then press the Return key.

• On the RCA-E, select the “Teach/Play” screen, scroll until “*Home Return” is displayed, and then

press the Return key.

• On the RCB-J, the “Operation Key  “Home Return” screen will be displayed automatically. Press

the OPERATION key on this screen.  Overview of operation on the PC software Select an applicable position data in the main window, and then click the [Home] button.

For details, refer to the operation manual for the teaching pendant or PC software.

 Issuing a command from the PLC

Perform signal processing appropriate for the selected PIO pattern by referring to 7.2.2, “Absolute Specification.”

Issue a command after confirming that the position complete signal (PEND) has turned ON.

If home return cannot be performed, confirm that the *pause signal and servo ON signal are ON and that the safety circuit is released, and also check if any error message is displayed.

When home return completes, the home position will be established and stored in the position data. This position data will be backed up by the battery even after the power is cut off. Therefore, home return need not be performed after the power is reconnected. Note, however, that the battery retention period is approx. 250 hours after the power is cut off. If the controller is not operated for a longer period such as in a case where the equipment is exported overseas, the battery voltage will drop and the stored position data will be lost. If the position data is lost, an “Absolute encoder error (2)” alarm will occur the next time the power is turned on. If this alarm occurs, follow the same steps to reset the alarm and perform home return. Also, keep the power supplied for at least 48 hours to charge the battery.

(13) Set the target position, speed, acceleration/deceleration, positioning band and other data in the position

table.

For details on how to set these data, refer to the operation manual for the teaching pendant/PC software. Now, automatic operation can be performed via PLC link.

Timing chart at startup

Safety circuit condition

24-VDC power ON

Resetting the alarm

• RCA-T/E: Press the BEGIN/END key.

• RCB-J: Press the STOP key.

• PC software: Click the [Alarm] button.

• PLC command: Start signal (CSTR)/reset signal (RES)

Alarm output

Alarm code output

(PM8~PM1)

ALM lamp

*Pause input

Servo ON input

RUN lamp

Ready output

(SRDY)

Position complete output

(PEND)

Home return completion output

(HEND)

Home return operation

(*ALM)

(STP)

(SON)

Emergency stop is actuated or motor drive power is cut off

Initial parameter settings

Emergency stop is not actuated or motor drive power is supplied

* Keep the power supplied for

at least 48 hours to charge the battery.

6 msec or more

Pause is cancell e d

Start of movement

Lit

Home position

Mechanical end

Creation of position table using the teaching pendant or PC operation

Note: If parameter No. 25 (PIO pattern) i s set to “0: [Conventional],” “2: [64-point positi oning]”

or “5: [4 points],” the servo ON input and ready output are not provided.

7.2 How to Execute Home Return

First, force the position complete signal to turn ON by referring to 7.1, “How to Start.”

7.2.1 Standard Specification

 When the PIO pattern is “0: [Conventional]”

Select and input a desired command position number in which a target position is registered, and then input the start signal. Home return is executed first, and then the actuator moves to the target position. The home return completion (HEND) will turn ON at the home position, and upon reaching the target position the position complete (PEND) and completed position output (PM1 to PM8) will turn ON. To stop the actuator at the home position, set the target position to “0.”

 When the PIO pattern is “5: [4 points]”

Input the movement command to one of the four positions (ST0 to ST3). Home return is executed first, and then the actuator will move to the target position. The home return completion signal (HEND) will turn ON at the home position, and upon reaching the target position the position complete signal (PEND) and the complete signal for each corresponding position (PE1 to PE3) will turn ON. To stop the actuator at the home position, set the target position to “0” in position No. 0 (Rear end), and then input the rear end move signal (ST0).

 When the PIO pattern is other than “0: [Conventional]” or “5: [4 Points]”

Input the home return signal (HOME). When home return is complete, the home return completion (HEND) and position complete (PEND) will turn ON.

IAI America RCP2-CF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

CAUTION

CE Marking

Table of Contents

Safety Guide

1. Overview

1.1 Introduction

1.2 How to Read Model Number

1.3 Handling of Secondary Batteries for the Absolute Specification

1.4 Safety Precautions

1.5 Warranty Period and Scope of Warranty

2. Specifications

2.1 Basic Specifications

2.1.1 Backup Batteries for the Absolute Specification

2.1.2 Specifications of the Large-Capacity Type (RCP2-CF)

2.2 Name and Function of Each Part of the Controller

2.2.1 Names

2.2.2 Functions

2.3 External Dimensions

2.3.1 Standard Specification (RCP2-***-I )

2.3.2 Absolute Specification with Battery Bracket (RCP2-***-A- -K)

2.3.3 Large-Capacity Type (RCP2-CF-***)

3. Installation and Noise Elimination

3.1 Installation Environment

3.2 Power Supply

3.3 Noise Elimination and Grounding

3.4 Heat Radiation and Inst allation

4. Wiring

4.1 Internal Drive-Power Cutoff Relay Type (RCP2-C, RCP2-CF)

4.1.1 Configuration

4.1.2 External Connection Diagram

4.1.3 Wiring the Power Supply/Emergency-Stop Switch

4.2 External Drive-Power Cutoff Relay Type (RCP2-CG)

4.2.1 Configuration

4.2.2 External Connection Diagram

4.2.3 Wiring the Power Supply/Motor Power Cutoff Relay

4.3 Connecting the I/O Cables

4.4 Connecting the Actuator

4.4.1 Motor Extension Cable

4.4.2 Encoder Extension Cable  [Standard controller (2 A)]

4.5 Connecting the Communication Cable

5. I/O Signal Control and Signal Functions

5.1 PIO Patterns and Signal Assignments

5.1.1 Explanation of Signal Names

5.1.2 Signal Assignment Table for Respective PIO Patterns

5.2 Interface Circuit

5.2.1 External Input Specifications

5.2.2 External Output Specifications

5.3 Details of I/O Signal Functions

5.3.1. Details of Each Input Signal

5.3.2 Details of Each Output Signal

(Reference) Output Signal Changes in Each Mode

6. Data Entry <Basics>

6.1 Description of Position-Dat a Table

6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value

(3) SM type

(3) RSA/RSW type (4) RMA/RMW type

(5) RFA/RFW type

6.2 Explanation of Modes

6.2.1 Positioning Mode Push = 0

6.2.2 Push & Hold Mode Push = Other than 0

6.2.3 Speed Change during Movement

6.2.4 Operation at Different Acceleration and Deceleration Settings

6.2.5 Pause

6.2.6 Zone Signal Output

6.2.7 Home Return

6.2.8 Teaching Mode (Jogging/Teaching Using PIO)

6.2.9 Overview of the “4 Points” (Air Cylinder) Mode

6.3 Notes on the ROBO Gripper

7. Operation <Practical Steps>

7.1 How to Start

7.1.1 Standard Specification

7.1.2 Absolute Specification (Absolute Reset)

7.2 How to Execute Home Return

7.2.1 Standard Specification