IAI America RCS-C User Manual
RCS Series
ROBO Cylinder Controller
RCS-C Type
Operation Manual Nineteenth Edition
CAUTION
(1) Hold · Servo ON Signal
When operating the RCS (ROBO cylinder) controller, you will need to turn ON the Hold &
Servo ON signal Input Signal of PIO.
In case the Hold Stop Input Signal of PIO remains OFF, RCS controller will not move due
to hold status. Therefore, please be careful.
(2)
The 100-V controller looks the same as the 200-V controller. However, the 100-V
controller will be damaged if 200 V is supplied. Pay due attention when connecting
the controller to a power source.
(3) Position 0 may be output regardless of the actual position. At the timings specified below,
the position complete signal turns ON no matter where the actual position is. As a result,
the output status becomes “Position 0.”
1. When the power is turned on
2. When the emergency stop is reset
3. When the alarm is reset
4. When a reset is performed after hold
Be extra careful when using Position 0.
(4) With the absolute type, 0E5 (Encoder Reception Error) will be displayed under certain
conditions, such as when the power is first turned on after disconnecting the battery or PG
cable. This display does not indicate fault. Perform an absolute reset in accordance with
the specified procedure.
(5) Recommendation for backing up latest data
This controller uses nonvolatile memory to store position table data and parameters.
Although data in the memory is retained even after the power is cut off, the stored data will
be lost if the nonvolatile memory is damaged.
It is therefore recommended that you regularly back up the latest position table data and
parameters in case of accidental data loss. Regular backup will also let you restore data
quickly if the controller must be replaced for other reasons.
Use the following methods to back up data:
[1] Use the PC software to save the data to a CD or FD.
[2] Create a position table sheet or parameter sheet and keep a written record of backup.
Safety Precautions (Please read before using the product.)
Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as well
as the operating manuals and other related documentations for all equipment and peripheral devices connected
to this product in order to ensure the correct use of this product and connected equipment/devices. Those
performing installation, operation, maintenance and inspection of the product must have sufficient knowledge of
the relevant equipment and their safety. The precautions provided below are designed to help you use the
product safely and avoid bodily injury and/or property damage.
In this operating manual, safety precautions are classified as “Danger,” “Warning,” “Caution” and
“Note,” according to the degree of risk.
Danger
Failure to observe the instruction will result in an imminent danger leading to
death or serious injury.
Warning
Caution
It should be noted that the instructions under the Caution and Note headings may also lead to
serious consequences, if unheeded, depending on the situation.
All instructions contained herein provide vital information for ensuring safety. Please read the contents carefully
and handle the product with due caution.
Please keep this operating manual in a convenient place for quick reference whenever needed, and also make
sure that the manual will get to the end-user.
Note
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
[General]
Do not use this product for the following applications:
1. Medical equipment used to maintain, control or otherwise affect human life or physical health
2. Mechanisms and machinery designed for the purpose of moving or transporting people
3. Important safety parts of machinery
This product has not been planned or designed for applications requiring high levels of safety. Use of this
product in such applications may jeopardize the safety of human life. The warranty covers only the product as
it is delivered.
[Installation]
Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The product
may ignite, burn or explode.
Avoid using the product in a place where the main unit or controller may come in contact with water or oil
droplets.
Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the
cable length. Doing so may result in fire.
[Operation]
If you are using a pace maker or other mechanical implant, do not come within one meter of the product.
Doing so may cause the pace maker, etc., to malfunction due to the strong magnetic force generated by the
product.
Do not pour water onto the product. Spraying water over the product, washing it with water or using it in water
may cause the product to malfunction, resulting in injury, electric shock, fire, etc.
[Maintenance, Inspection, Repair]
Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in injury,
electric shock, fire, etc.
Do not disassemble and reassemble the product. Doing so may result in injury, electric shock, fire, etc.
Warning
[General]
Do not use the product outside the specifications. Using the product outside the specifications may cause it to
fail, stop functioning or sustain damage. It may also significantly reduce the service life of the product. In
particular, observe the maximum loading capacity and speed.
[Installation]
If the machine will stop in the case of system problem such as emergency stop or power failure, design a
safety circuit or other device that will prevent equipment damage or injury.
Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding: Grounding
resistance at 100 or less). Leakage current may cause electric shock or malfunction.
Before supplying power to and operating the product, always check the operation area of the equipment to
ensure safety. Supplying power to the product carelessly may cause electric shock or injury due to contact
with the moving parts.
Wire the product correctly by referring to the operation manual. Securely connect the cables and connectors
so that they will not be disconnected or come loose. Failure to do so may cause the product to malfunction or
cause fire.
[Operation]
Do not touch the terminal block or various switches while the power is supplied to the product. Failure to
observe this instruction may result in electric shock or malfunction.
Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.), confirm
that the servo is turned off (using the teaching pendant). Failure to observe this instruction may result in injury.
Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object or
pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock, malfunction, etc.
Turn off the power to the product in the event of power failure. Failure to do so may cause the product to
suddenly start moving when the power is restored, thus resulting in injury or product damage.
If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing to use
the product may result in product damage or fire.
If any of the internal protective devices (alarms) of the product has actuated, turn off the power immediately.
Continuing to use the product may result in product damage or injury due to malfunction. Once the power
supply is cut off, investigate and remove the cause and then turn on the power again.
If the LEDs on the product do not illuminate after turning on the power, turn off the power immediately. The
protective device (fuse, etc.) on the live side may remain active. Request repair to the IAI sales office from
which you purchased the product.
[Maintenance, Inspection, Repair]
Before conducting maintenance/inspection, parts replacement or other operations on the product, completely
shut down the power supply. At this time, take the following measures:
1. Display a sign that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER” at a conspicuous place,
in order to prevent a person other than the operator from accidentally turning on the power.
2. When two or more operators are to perform maintenance/inspection together, always call out every time
the power is turned on/off or an axis is moved in order to ensure safety.
[Disposal]
Do not throw the product into fire. The product may burst or generate toxic gases.
Caution
[Installation]
Do not use the product under direct sunlight (UV ray), in a place exposed to dust, salt or iron powder, in a
humid place, or in an atmosphere of organic solvent, phosphate-ester machine oil, etc. The product may lose
its function over a short period of time, or exhibit a sudden drop in performance or its service life may be
significantly reduced.
Do not use the product in an atmosphere of corrosive gases (sulfuric acid or hydrochloric acid), etc. Rust may
form and reduce the structural strength.
When using the product in any of the places specified below, provide a sufficient shield. Failure to do so may
result in malfunction:
1. Place where large current or high magnetic field is present
2. Place where welding or other operations are performed that cause arc discharge
3. Place subject to electrostatic noise
4. Place with potential exposure to radiation
Do not install the product in a place subject to large vibration or impact (4.9 m/s
result in the malfunctioning of the product.
Provide an emergency-stop device in a readily accessible position so the device can be actuated immediately
upon occurrence of a dangerous situation during operation. Lack of such device in an appropriate position
may result in injury.
Provide sufficient maintenance space when installing the product. Routine inspection and maintenance cannot
be performed without sufficient space, which will eventually cause the equipment to stop or the product to
sustain damage.
Do not hold the moving parts of the product or its cables during installation. It may result in injury.
Always use IAI’s genuine cables for connection between the controller and the actuator. Also use IAI’s
genuine products for the key component units such as the actuator, controller and teaching pendant.
2
or more). Doing so may
Before installing or adjusting the product or performing other operations on the product, display a sign that
reads, “WORK IN PROGRESS. DO NOT TURN ON POWER.” If the power is turned on inadvertently, injury
may result due to electric shock or sudden activation of an actuator.
[Operation]
Turn on the power to individual equipment one by one, starting from the equipment at the highest level in the
system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or product
damage.
Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.
Do not bring a floppy disk or other magnetic data storage medium within one meter of the product. The data
inside the floppy disk, etc., may be damaged due to the magnetic force generated by the magnet in the
product.
[Maintenance, Inspection, Repair]
Do not touch the terminals when performing an isolation resistance test. Electric shock may result. (Do not
perform any withstand voltage test on a product that uses DC power supply.)
Note
[Installation]
Do not place objects around the controller that will block airflows. Insufficient ventilation may damage the
controller.
Do not configure a control circuit that will cause the load to drop in case of power failure. Configure a control
circuit that will prevent the table or load from dropping when the power to the machine is cut off or an
emergency stop is actuated.
[Installation, Operation, Maintenance]
When handling the product, wear protective gloves, protective goggles, safety shoes or other necessary gear
to ensure safety.
[Disposal]
When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste.
Others
IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the items specified
in “Safety Precautions.”
If you have any question regarding the product, please contact your nearest IAI sales office. The addresses
and phone numbers of our sales offices are provided at the end of this operation manual.
Before Use
Caution
[1] Be sure to read this operation manual to ensure the proper use of this product.
[2] Unauthorized use or reproduction of a part or all of this operation manual is prohibited.
[3] IAI shall not be liable whatsoever for any loss or damage arising from a handling or operation not
specified in this operation manual.
[4] The information contained in this operation manual is subject to change without notice.
Action to Be Taken in Case of Emergency
* If this product is found to be in a dangerous condition, immediately turn off all power switches of the main
unit and connected equipment or immediately disconnect all power cables from the outlets. (“Dangerous
condition” refers to a situation where the product is generating abnormal heat or smoke or has ignited and
a fire or danger to human health is anticipated.)
Table of Contents
1. Note to the User ......................................................................................1
1.1 Introduction .................................................................................................................................. 1
1.2 How to Read Model Number ....................................................................................................... 2
1.3 Safety Precautions ...................................................................................................................... 3
1.4 Warranty Period and Scope of Warranty..................................................................................... 4
1.5 Installation Environment and Noise Elimination .......................................................................... 5
1.6 Heat Radiation and Installation.................................................................................................... 8
2. Specification for 24-VDC Input Power .....................................................9
2.1 Basic Specifications..................................................................................................................... 9
2.1.1 Backup Battery (Absolute Specification) .............................................................................. 10
2.2 Names and Functions of Parts .................................................................................................. 11
2.2.1 Names .................................................................................................................................. 11
2.2.2 Functions .............................................................................................................................. 11
2.2.3 Pin Assignments of the Communication Ports ..................................................................... 14
2.3 External Dimensional Diagram.................................................................................................. 16
2.3.1 Standard Specifications ........................................................................................................ 16
2.3.2 Absolute Specification .......................................................................................................... 17
2.4 Connection Method ................................................................................................................... 18
2.4.1 Standard Type....................................................................................................................... 18
2.4.2 Absolute Specifications......................................................................................................... 19
2.5 Supplied Cable .......................................................................................................................... 20
2.5.1 I/O Flat Cable........................................................................................................................ 20
2.5.2 Motor Extension Cable ......................................................................................................... 21
2.5.3 Encoder Extension Cable ..................................................................................................... 21
2.6 Wiring......................................................................................................................................... 22
2.6.1 Wiring for Power Supply/Emergency Stop ........................................................................... 22
2.6.2 External Connection Diagram............................................................................................... 23
2.6.3 PIO Interface......................................................................................................................... 24
2.6.4 External I/O Specifications.................................................................................................... 27
3. Input Power 100/200 VAC Specification ................................................29
3.1 Base Specification ..................................................................................................................... 29
3.1.1 Backup Battery (Absolute Specification) .............................................................................. 30
3.2 Names and Functions of Parts .................................................................................................. 32
3.2.1 Names .................................................................................................................................. 32
3.2.2 Functions .............................................................................................................................. 32
3.2.3 Signal Tables of Connectors and Terminal Blocks ............................................................... 36
3.3 External Dimensions.................................................................................................................. 38
3.3.1 Standard Type....................................................................................................................... 38
3.3.2 Absolute Specification .......................................................................................................... 39
3.4
Connection Method ................................................................................................................... 40
3.4.1 Standard Type....................................................................................................................... 40
3.4.2 Absolute Specifications......................................................................................................... 41
3.5 Supplied Cables ........................................................................................................................ 42
3.5.1 I/O Flat Cable........................................................................................................................ 42
3.5.2 Motor Extension Cable ......................................................................................................... 43
3.5.3 Encoder Extension Cable ..................................................................................................... 43
3.6 Wiring......................................................................................................................................... 44
3.6.1 Wiring for Power Supply/Emergency Stop ........................................................................... 44
3.6.2 External Connection Diagram............................................................................................... 45
3.6.3 PIO Interface......................................................................................................................... 46
3.6.4 100/200-V External I/O Specifications.................................................................................. 49
4. Data Entry <Basics>..............................................................................51
4.1 Description of Position-Data Table ............................................................................................ 52
4.2 Explanation of Modes ................................................................................................................ 56
4.3 Timing Chart .............................................................................................................................. 60
4.4 Items to Note on Gripper (RCS-G20) ........................................................................................ 61
5. Using the Controller <Practical Steps>..................................................62
5-1 How to Start (Standard Specification)........................................................................................ 62
5.2 How to Execute Absolute Reset (Absolute Specification) ......................................................... 63
5.3 Movement after Power On (Standard Type).............................................................................. 65
5.4 Positioning Mode (Back and Forth Movement between Two Points)........................................ 67
5.5 Push & Hold Mode..................................................................................................................... 69
5.6 Speed Change during Movement.............................................................................................. 71
5-7 Operation at Different Acceleration and Deceleration Settings................................................. 73
5.8 Pause......................................................................................................................................... 75
5.9 Zone Signal Output.................................................................................................................... 77
5.10 Returning Home ........................................................................................................................ 79
5.11 Incremental Moves .................................................................................................................... 81
5.12 Notes on Incremental Mode ...................................................................................................... 83
6. Parameters ............................................................................................85
6.1 Parameter Classification............................................................................................................ 85
6.2 Parameter List ........................................................................................................................... 85
6.3 Parameter Settings.................................................................................................................... 86
6.3.1 Parameters Relating to Actuator Stroke Range.................................................................... 86
6.3.2 Parameters Relating to Actuator Operating Characteristics................................................. 87
6.3.3 Parameters Relating to External Interface ........................................................................... 90
6.3.3 Servo Gain Adjustment......................................................................................................... 90
7. Troubleshooting.....................................................................................91
7.1 What to Do When A Problem Occurs ........................................................................................ 91
7.2 Alarm Level Classification ......................................................................................................... 92
7.3 Alarm Output by PIO ................................................................................................................. 92
7.4 Alarms, Causes and Actions...................................................................................................... 93
(1)
Message Alarms ................................................................................................................... 93
(2) Operation Cancellation Alarms............................................................................................. 94
(3) Cold Start Alarms.................................................................................................................. 96
7.5 Messages Displayed during Operations Using Teaching Pendant or PC Software.................. 99
* Appendix.................................................................................................101
Specification List of Supported Actuators ........................................................................................... 101
Example of Basic RCS Positioning Sequence ................................................................................... 104
Position Table Record (1/2) ................................................................................................................ 107
Parameter Record .............................................................................................................................. 108
1. Overview
1.1 Introduction
Thank you for purchasing the RCS controller. This manual explains the features and operating procedures of the
product.
If not used or handled properly, any 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.
Absolute Specification
The absolute RCS controller is able to perform positioning operation immediately after the power has
been input and an absolute reset performed. You need not perform home return every time the
power is reconnected. Other basic functions are the same as those of the standard RCS controller.
The absolute RCS controller is shipped without an absolute reset executed. It must be done by the
user.
Only RCS actuators of absolute specification can be used with the absolute RCS controller. It cannot
be used with RCS actuators of incremental specification.
Notes on installing the absolute-data backup battery
Be sure to follow the installation steps below to initialize the battery circuit and thereby prevent an
early consumption of the battery:
[1] Connect the encoder cable.
[2] Turn on the power.
[3] Install the absolute-data backup battery.
The above steps must always be followed when the encoder cable has been disconnected for
relocation, etc.
Actuator duty
It is recommended that IAI’s actuators be used at a duty of 50% or below as a guideline in view of the
relationship of service life and accuracy.
Duty is calculated by the formula below:
Duty (%) =
Controller version
A label on which a serial number is printed is attached on the right side of the controller.
The last two digits of the serial number, consisting of an alphabet and a number, indicate the version of your
controller.
Example) SERIAL No. ET352720 N5
In this example, the controller version is “N5.”
When the controller is updated to a higher version, the alphabet will change to a higher letter and the number
will increase. Take note that some controller specifications will vary depending on the version.
hours Operating
x 100
hours operating-Non hours Operating
1
* 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 referenced readily when necessary.
1.2 How to Read Model Number
<Series>
<Controller type>
C: Standard
<Applicable actuator>
[1] Actuator type
Slider type
SA4
SA5
SA6
SS SSR
SM SMR
Rod type
RA35 RA35R
RA45 RA45R
RA55 RA55R
RB7525
RB7530
RB7535
Flat type
F45
F55
Gripper
G20
Rotary
R10
R20
R30
[2] Encoder type
I: Incremental
A: Absolute
[3] Motor capacity
20 (20 W)
30 (30 W)
60 (60 W)
100 (100 W)
150 (150 W)
<I/O signal type>
P: PNP specification [Source]
Blank: NPN specification [Sink]
<CE compliance>
EU: CE-compliant
Blank: Not CE-compliant
<Input supply voltage>
0: 24 VDC
1: 100 VAC
2: 200 VAC
<Open network>
DV: DeviceNet specification
CC: CC-Link specification
PR: ProfiBus specification
Blank: Not network-ready
2
1.3 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 a genuine cable specified by IAI for connecting the actuator and RCS controller.
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, enclose 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 keep 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.
3
1.4 Warranty Period and Scope of Warranty
The RCS 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 condition 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.
4
1.5 Installation Environment and Noise Elimination
Pay due attention to the installation environment of the controller.
1.5.1 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
40C 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.
1.5.2 Power Supply
The power supply specification is 24 VDC, 100 VAC or 200 VAC depending on the controller type.
1.5.3 Noise Elimination and Grounding
(1) Wiring and power supply
[1] 100/200-VAC controller
PE on the power terminal block is a protective grounding terminal. Provide Class D grounding.
Use a grounding cable of 0.75 mm
cable.
Class D grounding
(protective grounding)
2
(AWG18) or larger. The grounding cable must be longer than the AC
100/200-VAC power supply
5
[2] 24-VDC controller
The power terminal block does not have a protective grounding terminal, but the user must separately
provide a noise elimination measure and grounding.
(2) Grounding for noise elimination
Regardless of whether the power supply is 100/200 VAC or 24 VDC, the controller must always be
grounded to eliminate noise.
[1] Connect the controller by directly screwing it onto a metal frame.
Protective grounding
100/200-V
controller
24-V
controller
(AC power supply)
(24 VDC)
Use a cable of
a maximum
possible size
and keep the
wiring distance
at a minimum.
Metal frame
[2] If the controller cannot
be screwed onto the
frame, connect it to the
frame as shown in the
figure at left.
[3] 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.
6
(3) 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.
7
1.6 Heat Radiation and Installation
Design the control panel size, controller layout and cooling method in such a way that the temperature around
the controller will not exceed 40C.
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 100 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.
Fan
50 mm or more
50 mm or more
100 mm or
more
Airflow
8
2. Specification for 24-VDC Input Power
2.1 Basic Specifications
Item Specification
Supply voltage
Type RA35 RA45, F45 RB75 (60 W) SA4, SA5 SA6
24 VDC 10%
Supply current [A]
Rating Peak
1.8 4.3 2.4 6.0 3.9 7.5 1.2 3.7 1.4 3.9
Maximum motor output 60 W (Torque limit x 2) / Other (x 3)
Surrounding air
temperature/humidity
0 to 40C, 85%RH or less
Surrrounding environment IP10, free from corrosive gases
Weight 540 g (Standard), 740 g (Absolute specification)
Protective functions
Regenerative voltage error, motor overcurrent, power-stage overheat,
encoder error, motor overload, overspeed
LED indicators RDY (ready), RUN, ALM (alarm), ENC (encoder error)
DI/DO interface 24 VDC, isolated
Start
8 dedicated
input ports
Command position number (4-bit binary)
* Pause
Reset
Servo ON
Completed position number (4-bit binary)
Input/output
Position complete
Home return completion
10 dedicated
output ports
Zone
* Alarm
* Emergency stop
Moving
Serial interface input/output
Number of positions 16
Data entry method Teaching pendant, PC software
Storage device EEPROM 8 kbytes, S-RAM 128 kbytes
Note: Supplying the power-supply port or any I/O port with a voltage beyond the specified level may
result in controller failure.
* indicate a b-contact signal.
9
2.1.1 Backup Battery (Absolute Specification)
(1) Battery Specification
Item Description
Model number AB-1
Type Lithium battery
Manufacturer Toshiba Battery Co., Ltd. (ER6VP)
Nominal voltage 3.6 V
Rated capacity 2000 mAh
Weight Approx. 8.5 g
Battery retention time Note 1)
Note 1) Approx. 100 A of current is consumed while data is backed up by the absolute data backup
battery (as opposed to approx. 4 A consumed while the main controller power is on).
* Do not modify or extend the wires. It may cause failure.
* The battery is replaced together with the board. Since what you will replace is not the battery alone,
always use the product specified by IAI.
* An absolute reset must be performed after the battery has been replaced.
Approx. 20,000 hours (at surrounding air temperature of
20C).
10
2.2 Names and Functions of Parts
2.2.1 Names
[6] Main communication port connector
(PORT IN)
[7] Regenerative resistor connector (RB)
[8] Power/emergency-stop terminal block
2.2.2 Functions
[1] Battery connector
[2] Motor connector (M)
[3] Brake release switch (BK)
[4] SIO connector (SIO)
[1] Battery connector (BAT)
(absolute specification)
[2] Motor connector (M)
[3] Brake release switch (BK)
[4] SIO connector (SIO)
[5] Port switch (PORT)
A connector for absolute-data backup battery (absolute specification).
A connector for the actuator’s motor power cable.
This switch is available only when the brake option is selected.
RLS: Brake is forcibly released
NOM: Brake is in use (Normal setting)
A connector for linking another controller when two or more controllers are connected.
[9] LED indicators
[10] Encoder/brake connector
(ENC)
[11] Piano switches 3
(SW3)
[12] Piano switches 2
(SW2)
[13] Piano switches 1
(SW1)
[14] PIO connector (PIO)
11
[5] Port switch (PORT)
ON: The PORT IN port (teaching pendant/PC software) becomes active. If a dedicated teaching pendant
or cable is not connected to this port, the controller will recognize an emergency-stop condition.
OFF: The PORT IN port (teaching pendant/PC software) becomes inactive. (Controller-to-controller
communication is possible.)
[6] Main communication port connector (PORT IN)
A connector for receiving the communication cable from a dedicated teaching pendant or external
equipment. It also receives a controller link cable when two or more axes are connected.
[7] Regenerative resistor connector (RB)
A connector for regenerative discharge resistor.
The controller will come with a regenerative resistor if the specified actuator capacity is 30 W or above.
However, connection is basically optional, and it should be connected when a regenerative discharge
error occurs. The error code of the regenerative discharge error is “0C9.”
[8] Power/emergency-stop terminal block
EMG: Both terminals are used to connect an emergency-stop switch. (The controller is shipped with the
EMG terminals shorted.)
24V: Connect the positive side of the 24-VDC power supply.
N: Connect the negative side of the 24-VDC power supply.
[9] LEDs
RDY (green): Indicate that the CPU is operating normally.
RUN (green): This LED turns on while the actuator is moving.
ALM (red): This LED remains lit while an alarm is present.
ENC (orange): This LED turns on when the encoder cable is open or otherwise the encoder cannot be
recognized.
[10] Encoder/brake connector (ENC)
A connector for encoder/brake power cable.
[11] Piano switches 3
Switches for selecting the encoder voltage. Use these switches if a custom cable is used and possibility of
voltage drop must be taken into consideration.
Set switches 1 and 2 to ON or OFF in accordance with the cable length.
1 2 Cable length
ON OFF 1 to 5 m
OFF ON 5 to 10 m
ON ON 10 to 15 m
Note: All piano switches are designated as Nos. 1, 2, etc., from the bottom.
With the piano switch in front of you, tilt it to the right side to turn on the switch, or tilt it to the
left side to turn off the switch.
[12] Piano switches 2
1 (bottom): ABS-CLR. Clear the absolute encoder data. Set this switch to ON when performing an
absolute reset. --- Normally OFF
2 (top): FWP. Write protect switch. Set this switch to ON when performing a remote upload.
--- Normally OFF
12
[13] Piano switches 1 (SW1)
Nos. 1 to 4 --- Address switches
Use these switches to set the address of the applicable actuator if two or more axes are connected to the
SIO connector. A desired address between 0 to 15 can be set.
(The factory setting is OFF for all of switch Nos. 1 to 4. This setting represents a condition where only one
axis is used.)
Use these switches to set a desired address for each controller. Make sure no address is duplicated
among the controllers. As long as they are unique, the addresses may not be contiguous and missing
numbers are allowed.
Address
1 2 3 4
Piano switch numbers
0 OFF OFF OFF OFF
1 ON OFF OFF OFF
2 OFF ON OFF OFF
3 ON ON OFF OFF
4 OFF OFF ON OFF
5 ON OFF ON OFF
6 OFF ON ON OFF
7 ON ON ON OFF
8 OFF OFF OFF ON
9 ON OFF OFF ON
10 OFF ON OFF ON
11 ON ON OFF ON
12 OFF OFF ON ON
13 ON OFF ON ON
14 OFF ON ON ON
15 ON ON ON ON
The controller link cable is 200
mm long.
A maximum of 16 controllers can
be connected.
Note: If multiple controllers are connected using link cables, the EMERGENCY STOP/ENABLE SW
on the teaching pendant (optional) becomes effective only with respect to the controller to
which the teaching pendant is connected.
[14] PIO connector (PIO)
A connector for PIO cable.
13
2.2.3 Pin Assignments of the Communication Ports
Pin assignments of the SIO connector
Pin No. Signal name Function
1 (+5V) (5-VDC power output) or (preliminary signal terminal)
2 SGA Positive logic side of the line transceiver I/O
3 GND Communication ground
4 SGB Negative logic side of the line transceiver I/O
5 GND Communication ground
6 (+5V) 5-VDC power output
Pin assignments of the main communication port
Pin No. Signal name Function
1 SGA Serial communication
2 SGB Serial communication
3 5V 5-V power output
4 EMGS Emergency-stop status
5 EMGA *1
6 24V 24-V power output
7 GND Ground
*1 Used to actuate an emergency stop (contact b).
Short these pins to cancel an emergency stop.
Motor connector [Molex 5569-04A1]
8 ENGB *1
Pin No. Signal name Connected wire
1 U Motor phase U
2 V Motor phase V
3 W Motor phase W
4 (NC)
14
Encoder/brake connector [High-density D-sub, DE-15 type]
Pin No. Signal name Connected wire
1 EN A+ Encoder A+
2 EN A– Encoder A3 EN B+ Encoder B+
4 EN B– Encoder B5 EN Z+ Encoder Z+
6 EN Z– Encoder Z7 SD+ Encoder SD+
8 SD– Encoder SD-
9 BAT+ (Battery+)
10 GND (Battery-)
11 EN 5 Encoder 5V+
12 EN GND Encoder COM13 BK N Brake14 BK P Brake+
15 FG Shield
Power/emergency-stop terminal block [Sato ML-800S IH (4P)]
Signal Name Connected wire
[2]
[1]
These terminals are connected to the emergency stop
circuit.
24 V is output to [1].
(These terminals have been shorted prior to shipment.)
24 V Positive side of the 24-V power supply
N Negative side of the 24-V power supply
24 V and ENG [1] are connected internally.
15
2.3 External Dimensional Diagram
2.3.1 Standard Specifications
5
16
2.3.2 Absolute Specification
5
17
2.4 Connection Method
2.4.1 Standard Type
Teaching pendant
<RCA-T/TD>
Optional
Cable length: 5 m
External unit
<RCA-105-5>
Optional
Cable length: 5 m
PC
PC software
<RCA-101-MW>
Optional
EMG switch
24-VDC
power
supply
ROBO Cylinder <RCS>
The cables are optional.
Host system <PLC>
Supplied flat
cable
Cable length: 2 m
External unit
<RCA-105-5>
Optional
Cable length: 5 m
Do not insert/remove the
connectors when the power is
on, except for the main
communication port connector
(PORT IN). To insert/remove the
PORT IN connector, do so after
turning the PORT switch to OFF.
18
2.4.2 Absolute Specifications
Battery
ROBO Cylinder <RCS>
The absolute specification
cannot be used with a
standard actuator.
The cables are optional.
Other connections are the
same as those of the
standard type.
19
2.5 Supplied Cable
2.5.1 I/O Flat Cable
Accessory
No Signal name Color No Signal name Color No Signal name Color No Signal name Color
1 COM-OA Brown-1 11 NC Brown-2 21 COM-IA Brown-3 31 NC Brown-4
2 COM-OA Red-1 12
3 COM-OB Orange-1 13 NC Orange-2 23 COM-IB Orange-3 33 NC Orange-4
4 COM-OB Yellow-1 14
5 NC Green-1 15 NC Green-2 25 NC Green-3 35 NC Green-4
6 *Alarm Blue-1 16
7 NC Purple-1 17 Moving Purple-2 27 NC Purple-3 37 NC Purple-4
8 Zone Gray-1 18
9 NC White-1 19
Home return
10
completion
• Optional
I/O connector
No Signal name Color No Signal name Color No Signal name Color No Signal name Color
1 COM-OA Brown-1 11 NC Brown-2 1 COM-IA Brown-1 11 NC Brown-2
2 COM-OA Red-1 12 Position complete Red-2 2 COM-IA Red-1 12 Start Red-2
3 COM-OB Orange-1 13 NC Orange-2 3 COM-IB Orange-1 13 NC Orange-2
4 COM-OB Yellow-1 14
5 NC Green-1 15 NC Green-2 5 NC Green-1 15 NC Green-2
6 *Alarm Blue-1 16
7 NC Purple-1 17 Moving Purple-2 7 NC Purple-1 17 NC Purple-2
8 Zone Gray-1 18
9 NC White-1 19 *Emergency stop White-2 9 NC White-1 19 NC White-2
Home return
10
completion
* The I/O connector (40P) is the same as the above accessory
I/O connector (40P)
Completed
position 8
Completed
position 4
Completed
position 2
*Emergency
Black-1 20
Completed
position 1
Position
complete
stop
I/O connector (40P)
Red-2 22 COM-IA Red-3 32 Start Red-4
Yellow-2 24 COM-IB Yellow-3 34
Blue-2 26 *Pause Blue-3 36
Gray-2 28 Servo ON Gray-3 38
White-2 29 NC White-3 39 NC White-4
Black-2 30 Reset Black-3 40
Flat cable
(Split position)
Output
connector
Command
position 8
Command
position 4
Command
position 2
Command
position 1
Flat cable
(Omron)
Input connector
(Omron)
(Omron)
[A] Output connector (20P) [B] Input connector (20P)
Black-1 20
Completed position
8
Completed position
4
Completed position
2
Completed position
1
Yellow-2 4 COM-IB Yellow-1 14
Blue-2 6 *Pause Blue-1 16
Gray-2 8 Servo ON Gray-1 18
Black-2 10 Reset Black-1 20
Command
position 8
Command
position 4
Command
position 2
Command
position 1
Yellow-4
Blue-4
Gray-4
Black-4
[A]
[B]
Yellow-2
Blue-2
Gray-2
Black-2
20
Loading...