IAI America RCP2-CF User Manual
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
0
Conventional
This pattern is compatible with the pin assignments of the RCP controller.
1
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.
2
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.
3
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.
4
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.
5
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.
Table of Contents
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
Pre-1
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
Pre-2
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)
3
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
A
1.2 How to Read Model Number
Controller with a power-supply capacity of 2 A
<Series>
<Safety circuit type>
C: Built-in cutoff relay
CG: External cutoff relay
<Actuator type>
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)
<Supply voltage>
<Motor type>
PM: Pulse motor
<Encoder type>
I: Incremental
: Absolute
Gripper
Rotary
Controller with a power-supply capacity of 6 A (Large-capacity type)
<Series>
<Safety circuit type>
CF: Built-in cutoff relay
<Actuator type>
High-speed ball-screw type
High-thrust rod type
Waterproof type
<I/O signal type>
Blank: NPN (sink type)
P: PNP (source type)
<Supply voltage>
<Motor type>
PM: Pulse motor
<Encoder type>
I: Incremental
2
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.
3
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.
4
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.
5
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 40C
Not subject to corrosive gases.
-10 to 65C
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.
6
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 20C)
Approx. 250 hours (when the batteries are fully charged, at
surrounding air temperature of 20C)
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 +30C) to
prevent extreme temperatures from negatively affecting the charging efficiency.
Temperatures exceeding 45C may cause performance deterioration or the leakage of
battery fluid.
7
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
8
Surrounding air
temperature
Surrounding
environment
500 VDC, 10 M
0 to 40C
Not subject to corrosive gases.
-10 to 65C
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
9
[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
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. (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)
10
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