SMC Networks RCS2, RGD5C, RGS7BD, RA4D, RGS4D User Manual

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Motor Straight Type (Coupling Type): RA4C, RA5C, RGS4C, RGS5C, RGD4C and RGD5C Motor Straight Type (Built-in Type): RA4D, RA7AD, RA7BD, RGS4D and RGS7AD

Motor Reversing Type: RA4R and RA5R Flat Type F5D

RCS2W Actuators, Dustproof/Splash-proof Specification

Motor Straight Type (Coupling Type): RA4C Motor Straight Type (Built-in Type): RA4D Motor Reversing Type: RA4R

ROBO Cylinder

Rod Type

RCS2 Actuators

RGS7BD, RGD4D, RGD7AD and RGD7BD

Operating Manual

Third Edition

IAI America, Inc.

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. T he 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]

z Do not use this product for the following applications:

1. Medical equipment use d 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]

z Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The

product may ignite, burn or explode.

z When installing the product, be sure to securely support and affix it (including the work). Failure to do

so may cause the product to tip over, drop or malfunction, resulting in injury.

z Avoid using the product in a place where the main unit or controller may come in contact with water or

oil droplets.

z 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]

z Do not enter the machine’s range of operation while the product is operating or standing by. The

actuator may move suddenly, causing injury.

z 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]

z Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in

injury, electric shock, fire, etc.

z Do not disassemble and reassemble the components relating to the basic structure of the product or its

performance and function. Doing so may result in injury, electric shock, fire, etc.

Warning

[General]

z 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]

z 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.

z 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.

z 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]

z 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.

z 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.

z 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.

z 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.

z If noise or abnormally high vibration is detected, stop the operation immediately. Continuing to use the

product may result in product damage, malfunction due to damage, runaway machine, etc.

z If any of the product’s protective functions (alarms) has actuated, turn off the power immediately.

Continuing to use the product may result in injury due to product malfunction, or cause product breakdown or damage. After the power has been cut off, identify and remove the cause of the problem, and then reconnect the power.

z Do not step on the product, use it as a footstool or place any object on it. You may slip and fall or the

product may tip over or drop, resulting in injury. Malfunction, runaway product, etc., may also result due to product breakdown or damage.

[Maintenance, Inspection, Repair] z Before commencing maintenance/inspection, servicing, replacement or any other work on the product,

be sure to completely cut off the power supply to the product. Also take heed of the following precautions:

1. Put up a sign bearing “WORK IN PROGRESS. DO NOT TURN ON POWER” or other warning statement to that effect, to prevent a bystander from accidentally turning on the power.

2. If multiple operators work together to perform maintenance/inspection work, the operators should always give verbal cues to one another to ensure safety before turning on/off the power or moving any axis.

[Disposal] z Do not throw the product into flames. The product may explode or toxic gases may generate.

Caution

[Installation]

z Do not use the product in a place exposed to direct sunlight (ultraviolet ray), dusty place or place

where air contains salt or iron powder, humid place, or in any ambience where the product may come in contact with organic solvent, hydraulic oil containing phosphate ester, etc. If used in theses places/ambiences, the product may lose its function over a short period of time or suffer rapid performance deterioration, or the service life of the product may be reduced.

z Do not use the product in an ambience where it may come in contact with corrosive gases (sulfuric

acid, hydrochloric acid, etc.). The product may lose its strength due to rust.

z Provide sufficient shielding measures if the product is used in any of the following places. If proper

measures are not taken, the product may malfunction:

1. Place where large current or strong magnetic field generates

2. Place where arc discharge occurs due to welding work, etc.

3. Place where noise generates due to electrostatic, etc.

4. Place where the product may come in contact with radiation

z Do not install the product in a place subject to vibration or shock. z Provide an emergency stop device in an easily accessible position so the device can be immediately

actuated should danger occur during operation. Failure to do so may result in injury.

z Provide sufficient maintenance space when installing the product. If sufficient space is not available,

daily inspection, maintenance and other necessary work cannot be carried out, resulting in system shutdown or product damage.

z When transporting or installing the product, support the product using a lift or suspension equipment or

carry it with multiple operators working together, an d exe rc is e du e ca ution to ensure safety .

z When installing the product, do not hold the moving parts or cables of the product. Doing so may result

in injury.

z Use IAI’s genuine cables to connect the actuator an d controller. Also use IAI’s genuine components for

the actuator, controller, teaching pendant, etc.

z The brake mechanism is designed to prevent the slider from dropping upon turning off the power when

the actuator is installed vertically. Do not use the brake mechanism as a safety brake.

z When installing, adjusting or carrying out any other work on the actuator, put up a sign bearing “WORK

IN PROGRESS. DO NOT TURN ON POWER” or other warning statement to that effect, to prevent the product from being powered on accidentally. If the power is turned on accidentally, injury may result due to electric shock or sudden movement of the actuator.

[Operation]

z 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.

z Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury. z Do not step on the product, use it as a footstool or place any object on it. It may cause scoring, dents

or deformation of the driving part, resulting in product damage, unintended stopping due to damage, or performance drop.

[Maintenance, Inspection, Repair]

z Wear protective goggles when applying grease to the actuator. Failure to do so may result in eye

inflammation due to spattered grease.

[Installation]

z If the product is used in a vertical setup, be sure to use the vertical specification (with brake). z Protection covers or other guards must be provided for the moving parts of the equipment to avoid

direct contact with the operators.

z Do not configure a control circuit that will cause the work to drop in case of power failure. Configure a

control circuit that will prevent the table or work from dropping when the power to the machine is cut off or an emergency stop is actuated.

z The following conditions must be met in order to improve the straightness of the table movement and

ensure the smooth movement of the ball screw and linear guides:

1. Flatness of the mounting surface must be within 0. 05 mm.

2. The mounting surface area must be large enough to ensure the rigidity of the actuator.

[Installation, Operation, Maintenance]

z When handling the product, wear protective gloves, protective goggles, safety shoes or other

necessary gear to ensure safety.

[Maintenance, Inspection, Repair]

z When performing maintenance, apply the specified grease to the guides and ball screw. Pay special

attention not to let fluoride grease mix with lithium grease. The machine may be damaged due to poor lubrication, increased resistance, etc.

[Disposal]

z When the product becomes no longer usable or necessary, dispose of it properly as an industrial

waste.

Note

Others

 IAI shall not be liable whatsoever for any loss or damage arising from a failure to

observe the items specified in “Safety Precautions.”

Prohibited Handling of Cables

When designing an application system using IAI’s actuators and controllers, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway system. This section explains prohibited handling of cables. Read the information carefully to connect the cables properly.

1. Do not let the cable flex at a single point.

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

Steel band (piano wire)

Bundle loosely.

3. Do not pull the cable with a strong force.

4. Do not let the cable receive a turning force at a

single point.

Do not pinch, drop a heavy object onto or cut

the cable.

Use a curly

cable.

5. When fixing the cable, provide a moderate slack

and do not tension it too tight.

Do not use a spiral tube where the cable flexes frequently.

7. Notes on using cable bearers

z Do not let the cable get tangled or kinked in a cable bearer or flexible tube. When bundling the cable,

keep a certain degree of flexibility (so that the cable will not become too taut when bent).

z Do not cause the cables to occupy more than

60% of the space in the cable bearer.

Cable

z The supplied cables are not robot cables. Accordingly,

never store the cables in a cable b earer.

z Always use a robot cable

for each relay cable.

z Use a cable bearer with a bending

radius (r) of 50 mm or greater.

Bending radius (r)

z Do not lay signal lines together with circuit lines

that create a strong electric field.

Cable bearer

Power line

Signal lines (flat cable)

Duct

Table of Contents

1. Foreword ................. ... ... ...... ... ... ....... ... ... ... ...... ... ... .... ...... ... ... ...... ... .... ... ...... ... ... ... ..............................1

2. Safety Precautions .................................... ... ... ... ....... ... ... ... ...... ... ... ....... ... ... ... ...... ... ... .... . ...................1

2.1 Basic Operating Instructions ...................................................................................... .....1

2.2 Maintenance and Inspection ................................... ........................................................1

3. Warranty................................. ... ... ....... ... ... ... ...... ... .... ... ...... ... ... ... ....... ... ... ... ...... ... ... ...........................2

3.1 Warranty Period...............................................................................................................2

3.2 Scope of Warranty................................................................ ................................ ...........2

4. Names of the Parts......................................................................................... .................................. ..3

4.1 Motor Straight Type (Coupling Type): No Guide............................. ..... ... ... ..... ... .. ... ..... ...3

z RCS2-RA4C................................................................................................................3

4.2 Motor Straight Type (Built-in Type): No Guide................................................................4

z RCS2-RA4D................................................................................................................4

4.3 Motor Reversing Type: No Guide................................................................. ...................5

z RCS2-RA4R................................................................................................................5

4.4 Motor Straight Type (Coupling Type): Single-guide Type ........................................... ...6

z RCS2-RGS4C.............................................................................................................6

4.5 Motor Straight Type (Coupling Type): Double-guide Type.......................... ...................7

z RCS2-RGD4C........................................................................ .....................................7

4.6 Motor Straight Type (Coupling Type): No Guide............................. ..... ... ... ..... ... .. ... ..... ...8

z RCS2-RA5C................................................................................................................8

4.7 Motor Reversing Type: No Guide................................................................. ...................8

z RCS2-RA5R................................................................................................................8

4.8 Motor Straight Type (Coupling Type): Single-guide Type ........................................... ...9

z RCS2-RGS5C.............................................................................................................9

4.9 Motor Straight Type (Coupling Type): Double-guide Type.......................... ...................9

z RCS2-RGD5C........................................................................ .....................................9

4.10 Short Type .......................... ..... ... ..... ... ..... ... .. ...... .. ...... .. ... ..... ... ..... ... ..... ... ... ..... ... ..... ... ...10

z RCS2-RA7A(B)D ........................................................................................ ..............10

4.11 Flat Type............................................................................. ...........................................10

z RCS2-F5D.................................................................................................................10

4.12 Dustproof/Splash-proof Motor Straight Type (Coupling Type) .....................................11

z RCS2W-RA4C ............................................... ...........................................................11

5. Transporting and Handling................................................................. ... ... ... ...... ... ... .... ... ..................12

5.1 Handling the Actuator .............................. ... .. ...... .. ...... .. ... ..... ... ..... ... ... ..... ... ..... ... .. ...... .. .12

5.1.1 Handling the Packed Unit......................................... ..... ... ... ..... ... ..... ... .. ...... .. ... ..... .12

5.1.2 Handling the Actuator After It is Unpacked......................................................... ...12

5.2 Handling the Actuator Assembly.................................................. ................................ .13

5.2.1 Condition of Shipment from IAI (Ass embled).........................................................13

5.2.2 Handling after Assembly with Peripheral Equipment.............................................13

6. Operating and Storage Environment................................. ..............................................................14

6.1 Operating Environment.................................... ..... ... ... ..... ... .. ...... .. ...... .. ... ..... ... ... ..... ... ...14

6.2 Storage Environment.................................................................................................. ...14

7. Installation .................................................... ... ... .... ...... ... ... ... ...... ... .... ...... ... ... ... ...... . ........................15

7.1 Installing the Main Body .................................................................. ..............................15

8. Wiring Cable................................................................. ...... ... ... ... ...... .... ... ... ...... ... ... ... ......................27

9. Connecting the Air Tube of the RCS2W Dustproof/Splash-proof Type...........................................28

10. Maximum Speed ............................................................................................................................29

11. Load on the Actuator......................................................................................................................30

12. Actuators with a Switch (Optional).................................................................................................30

13. High Acceleration/Deceleration Option..........................................................................................31

13.1 Applicable Actuator Models........................ ...................................................................31

13.2 Specifications of High Acceleration/Deceleration Actuators.........................................31

13.3 Notes........................................................................ ......................................................32

13.4 Applicable Controller Models (SCON, SSEL, X-SEL)...................................................32

14. Maintenance...................................................................................................................................33

14.1 Maintenance Schedule............................................ ......................................................33

14.2 Visual Inspection of the Machine Exterior.................................. ................................ ...33

14.3 Cleaning........................................................ .................................................................33

14.4 Applying Grease to the Sliding Surface of the Rod ..................................................... .34

14.5 Reduction Belt [Motor Reversing Type] ............................................... .........................35

14.5.1 Inspecting the Belt..................................................................................................35

14.5.2 Applicable Belt.......................... ... .. ...... .. ... ..... ... ..... ... ... ..... ... ..... ... .. ...... .. ...... .. ... ..... .35

14.5.3 Adjusting the Belt Tension (RA4R Type) ............................ ...................................36

14.5.4 Adjusting the Belt Tension (RA5R) ........................................................................37

14.5.5 Replacing the Belt of the Motor Reversing Type: RA4R Type ..............................38

12.5.6 Replacing the Belt of the Motor Reversing Type: RA5R Type ..............................43

14.6 Replacing the Motor.......................................................................................................46

14.6.1 Replacing the Motor of the Motor Straight Type (Coupling Type): RA4C Type....46

14.6.2 Replacing the Motor of the Motor Reversing Type: RA4R Type........................ .. .53

14.6.3 Replacin g the Motor of the Motor Reversing Type: RA5R Type ...........................59

14.7 Replacing the Bellows of the RCAW Dustproof/Splash-proof Type.............................62

15. Cable Drawings..............................................................................................................................65

1. Foreword

Thank you for purchasing an IAI product. This manual explains the structure, correct operation and maintenance of the actuator. Please read this manual carefully before using the product. For more complete information on operating the actuator, please also refer to the controller operating manual.

2. Safety Precautions

2.1 Basic Operating Instructions

• Please do not attempt to use or operate the actuator in any manner not indicated in this manual or the controller manual.

• Please be sure to use only the cable provided by IAI to connect the actuator and controller.

• Please do not allow people within the moving range of the unit when it is in operation or when the

power is ON since this is dangerous.

2.2 Maintenance and Inspection

• When doing maintenance and inspection work, always shut down the controller power first.

• When doing inspection, make sure that no one can inadvertently turn the power ON.

• Make sure that a sign indicating work in progress is clearly visible.

• If several persons are working, be sure to watch out for each other's safety. In particular, check before

turning power ON or OFF and let others know if you are doing work involving axis movement.

(Note)

• The content of this manual is subject to change without notice for the purpose of improvement.

• This manual was created with utmost attention to accuracy. Should you find any error, however, or if

you have any question, please contact IAI’s Sales Engineering or Technical Service Section.

3. Warranty

3.1 Warranty Period

Warranty period shall be either of the following periods whichever ends first:

• 18 months after shipment from our factory

• 12 months after delivery to a specified location

• 2500 hours of operation time

3.2 Scope of Warranty

If a breakdown occurs within the period specified above and is due to the manufacturer's error, we will repair the unit at no cost. However, the following items are not covered by this warranty.

• Faded paint or other changes that occur naturally over time.

• Consumable components that wear out with use (stainless sheet, etc.).

• Unit seems to be noisy or similar impressions that do not affect machinery performance.

• Damage resulting from improper handling by the user or lack of proper maintenance.

• Any alterations made by other than IAI or its representatives.

• Breakdowns caused by using controllers made by other manufacturers.

• Any damages caused by fire and other natural disasters or accidents.

The warranty pertains to the purchased product itself and does not cover any damages that might arise from a breakdown of the supplied product. Any repairs will be done at our factory. Even if the product is still covered under the warranty period, we will assess a separate charge for sending technicians to the customer's site.

4. Names of the Parts

The names of the actuator parts are indicated below . In this manual, the right and left are determined by viewing the actuator from the top and from the motor

side.

4.1 Motor Straight Type (Coupling Type): No Guide

z RCS2-RA4C

Rod side

Rod

Rod cove

Rod tip adapte

Right

Left

Cylinder tube

Motor side

Head cove

Motor unit

Cable

Caution: The cable directly connected to the actuator is not robot cable even when ordered

with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

4.2 Motor Straight Type (Built-in Type): No Guide

z RCS2-RA4D

Rod side

Rod

Rod tip adapte

Rod cove

Cylinder tube

Right

Left

Motor side

Head cove

Motor unit

Cable

Caution: The cable directly connected to the actuator is not robot cable even when ordered

with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

4.3 Motor Reversing Type: No Guide

z RCS2-RA4R

Rod side Motor side

Cable

Rod tip adapte

Rod

Rod cove

Right

Left

Motor unit

Cylinder tube

Pulley case

Head cove

Caution: The cable directly connected to the actuator is not robot cable even when ordered

with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

4.4 Motor Straight Type (Coupling Type): Single-guide Type

z RCS2-RGS4C

Rod side Motor side

Guide bracket

Rod

Guide bearing

Guide rod

Rod cove

Cylinder tube

Right

Left

Head cove

Motor unit

Cable

Caution: The cable directly connected to the actuator is not robot cable even when ordered

with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

4.5 Motor Straight Type (Coupling Type): Double-guide Type

z RCS2-RGD4C

Guide bracket

Rod side

Rod

Guide bearing

Rod cove

Guide rod

Cylinder tube

Head cove

Right

Left

Motor unit

Motor

side

Cable

Caution: The cable directly connected to the actuator is not robot cable even when ordered

with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

The names of respective actuato r part s are indic ate d be low. In this manual, the right and left are determined by viewing the actuator from the top and from the motor side when the actuator is placed horizontally. “Front” indicates the opposite side of the motor.

4.6 Motor Straight Type (Coupling Type): No Guide

z RCS2-RA5C

Right

Front Motor side

Rod

luminum frame

Left

Connector box

Rod tip adapter

Motor housing

Encoder cover

4.7 Motor Reversing Type: No Guide

z RCS2-RA5R

Pulley cover

4.8 Motor Straight Type (Coupling Type): Single-guide Type

z RCS2-RGS5C

Guide bearing

4.9 Motor Straight Type (Coupling Type): Double-guide Type

z RCS2-RGD5C

Guide bracket

Mounting bracket

Guide bearing

Guide rod

luminum frame

Guide rod

4.10 Short Type

z RCS2-RA7A(B)D

Front Motor side

screws (4 locations) Never touch these

screws.

4.11 Flat Type

z RCS2-F5D

nti-vibration

Rod tip adapter

Motor housing

Right

Left

luminum frame

Slider

Connector box

Encoder cover

Connector box

Encoder cover

4.12 Dustproof/Splash-proof Motor Straight Type (Coupling Type)

z RCS2W-RA4C

Rod side Motor side

Intake/

Bellows

Rod

Rod tip adapter

exhaust port

Rod cove

Right

Left

Cylinder tube Head cove

Motor unit

Cable

Caution: The cable directly connected to the actuator is not robot cable even when ordered

with robot cable option. When designing, please be sure not to give repeated bending loads to this cable. The robot cable is applicable only to the connecting cables.

5. Transporting and Handling

5.1 Handling the Actuator

5.1.1 Handling the Packed Unit

Unless otherwise specified, each actuator (axis) is shipped individually. Please take care that the shipping box is not dropped or subjected to strong impact during transport.

• The operator should not carry heavy shipping boxes by themselves.

• If the shipping box is left standing, it s hould be in a horizontal position.

• Do not climb on top of the shipping box.

• Do not place heavy objects on top of the shipping box.

5.1.2 Handling the Actuator After It is Unpacked

Lift the actuator up by the base to remove it from the packing.

• When transporting the actuator, be careful not to hit it against nearby structures or object. In particular,

exercise caution to protect the motor unit and pulley case against impact.

• Do not exert excessive force on any part of the actuator.

• Be careful not to cause the cables to receive a tensile force.

Supplement) Please refer to Section 4 above for the names of the actuator parts.

5.2 Handling the Actuator Assembly

Pay attention to the following instructions w hen transp orting an as s e mbly of act ua to r axes.

5.2.1 Condition of Shipment from IAI (Assembled)

The actuators you have ordered are assembled at IAI, after which the assembly receives a shipping inspection and is shipped in an outer frame with skids.

The assembly is packed with the rod securely affixed so that it will not move unexpectedly during transportation. In the case of a combined unit, the actuator ends are secured to prevent swinging due to external vibration.

• The package is not designed with special considerations for protection against impact due to dropping or collision, so please handle the package with care. Also, do not place any heavy object on the outer frame, as it is not strong enough to withstand loads.

• When suspending the package using ropes, etc., pass the ropes from underneath the reinforcement frames at the bottom of the skids. When lifting with a forklift, also place the forks underneath the skids.

• Set down the package carefully so as not to apply impact to the assembly or cause it to bounce.

After unpacking, handle the actuator assembly correctly by observing the instructions given below.

5.2.2 Handling after Assembly with Peripheral Equipment

When transporting the actuators that have been assembled with peripheral equipment either at IAI or on your site, observe the instructions given below.

• Secure the rod so that it will not move suddenly while transporting the actuator.

• If any actuator end is protruding, secure it to prevent swinging due to external vibration.

• If the actuator ends are not secured, do not apply any impact force exceeding 0.3 G during

transportation.

• When suspending the actuator-assembled peripheral equipment using ropes, etc., make sure the ropes do not contact the actuators directly.

• Pass the ropes over appropriate cushion materials, and make sure the loads from the ropes will be received by the base of each actuator.

• Secure the end of the Y-axis using a separate rope to maintain the axis in a stable horizontal position. At this time, be careful not to apply loads on the screw cover.

• Be careful not to allow the brackets, covers and connector box of each actuator to receive loads. Also protect the cables from pinching or excessive deformation.

6. Operating and Storage Environment

6.1 Operating Environment

The actuator should be set up in an environment, which meets the following criteria:

• Avoid direct sunlight.

• Avoid radiant heat fro m strong heat sources such as a furnace.

• Ambient temperature should be 0 ~ 40°C.

• The humidity should be less than 85% and there should be no condensation.

• Avoid exposure to corrosive or combustible gases.

• The area should have very little dust and be suitable for normal assembly operations. (RCS2)

• Avoid exposure to oil mist or flu ids used in cutting. (RCS2)

• Ambient air should be free from cutting or grinding fluids containing sulfur.

• The unit should not be subject to impact or vibration.

• Avoid extreme electromagnetic waves, ultraviolet rays and radiation.

• The installation environment should be such that the operator can work without wearing protective

gears or clothes. (RCS2)

Work space needed for maintenance/inspection [Motor straight type] [Motor reversing type]

* If you are using the dustproof/splash-proof type (RCS2W type), consult IAI beforehand.

This product is not designed by considering chemical resistance. Contact IAI for splash-proof resistance to liquids other than w ate r.

250

6.2 Storage Environment

The storage environment should be similar to the operating environment. In addition, you must take precautions against condensation if the unit is to be stored for a long period of time. Unless there are special instructions, we do not include moisture absorption agents when shipping the unit. If you are storing the unit where condensation might occur, then you must treat the entire package or treat the unit itself after it is unpacked to prevent condensation. The unit can w ithstand up to 60°C during a short storage interval but only up to 50°C if the storage period is longer than one month.

300

250

7. Installation

7.1 Installing the Main Body

(1) Using screws on the rod or head side

Install the actuator using screws set on the rod or head side of the actuator. z Applicable model: RCS2-RA4

Rod

Straight type

Rod cove

Reversing type

Rod cove

Head cove

Cylinder tube

Cylinder tube Head cove

Type MA

RA4 type M30 x 1.5 M40 x 1.5

Motor unit

Pulley case

(2) Using screws on a flange (optional)

An optional flange is available for installing the actuator. Use this flange, if necessary. z Applicable model: RCS2-RA4

Straight type

Mounting hole

Affixing nut

Flange

Straight type

Mounting hole

Affixing nut

Flange

Mating material is steel Mating material is aluminum

Screw size M6 M6

Tightening torque 12.3 N-m 5.4 N-m

Reversing type

Affixing nut

Mounting hole

Flange

Reversing type

Affixing nut

Mounting hole

Flange

Mating material is steel Mating material is aluminum

Screw size M6 M6

Tightening torque 12.3 N-m 5.4 N-m

(3) Using screws on feet (optional)

Optional feet are available for installing the actuator. Use these feet, if necessary. z Applicable model: RCS2-RA4

Straight type

Mounting hole

Affixing nut

Mounting hole

Foot A

Foot B

Mounting hole

Reversing type

Affixing nut

Foot

Mating material is steel Mating material is aluminum

Screw size M6 M6

Tightening torque 12.3 N-m 5.4 N-m

Caution: Affix the actuator using two feet (optional), one in the front and the other in the back.

If affixed using only one foot in the front or back, the actuator may be negatively affected due to insufficient rigidity.

(4) Using screws on a trunnion (optional)

An optional trunnion is available for installing the actuator. Use this trunnion, if necessary. z Applicable model: RCS2-RA4

Straight type

Mounting hole

Affixing nut

Trunnion ring

Bracket B

Bracket A

Straight type

Mounting hole

Trunnion ring

Affixing nut

Bracket B

Bracket A

Mating material is steel Mating material is aluminum

Screw size M6 M6

Tightening torque 12.3 N-m 5.4 N-m

Bracket B

Mating material is steel Mating material is aluminum

Screw size M6 M6

Tightening torque 12.3 N-m 5.4 N-m

Caution: Exercise caution when installing the actuator horizontally using the optional clevis or

trunnion or any commercially available free joint, because the rod will receive the actuator weight. As a result, the bush may wear quickly or internal mechanical parts may be damaged. If the actuator is installed horizontally using any of the aforementioned means, add a guide or other appropriate mechanism to prevent the rod from receiving the actuator weight.

Caution: The optional clevis and trunnion are designed so that the fulcrum shaft can only

receive radial load. In a condition where play is not permitted or thrust load is received, the customer must design a separate bearing structure.

Caution: The optional clevis and trunnion provide structures whereby the bearing supports the

fulcrum shaft. Apply grease to the fulcrum shaft.

Reversing type

Mounting hole

Affixing nut

Bracket A

Trunnion ring

(5) Using screws on a clevis (optional)

An optional clevis is available for installing the actuator. Use this clevis, if necessary. z Applicable model: Motor reversing type RCS2-RA4R

Reversing type

Stopper ring

Clevis bracket

Mounting hole

Mating material is steel Mating material is aluminum

Screw size M8 M8

Tightening torque 30 N-m 12 N-m

Caution: Exercise caution when installing the actuator horizontally using the optional clevis or

Caution: The optional clevis and trunnion are designed so that the fulcrum shaft can only

receive radial load. In a condition where play is not permitted or thrust load is received, the customer must design a separate bearing structure.

Caution: The optional clevis and trunnion provide structures whereby the bearing supports the

fulcrum shaft. Apply grease to the fulcrum shaft.

(6) Using screws on a rear mounting bracket (optional)

An optional rear mounting bracket is available for installing the actuator. Use this rear mounting bracket, if necessary. z Applicable model: Motor reversing type RA4R

Reversing type

Tapped mounting hole

Type Tapped hole diameter Tapped depth Tightening torque

RA4 type M4 7 mm 1.8 N-m

(7) Double-guide type

Use the tapped holes in the bracket for installing an actuator of the double-guide type. z Applicable model: Double-guide type RGD4

Tapped mounting hole

Bracket A

Bracket B

Type Tapped hole diameter Tapped depth Tightening torque

RA4 type M5 8 mm 3.4 N-m

(8) Single-guide type

Use the tapped holes in the bracket for installing an actuator of the single-guide type. z Applicable model: Double-guide type RGD4

Tapped mounting hole

Bracket A

Bracket B

Type Tapped hole diameter Tapped depth Tightening torque

RA4 type M5 8 mm 3.4 N-m

(9) Using tapped mounting holes at the back

Applicable model: RA7 (excluding 50-mm stroke models) The RA7 type has tapped mounting holes at the back . Use these holes to install the actuator.

RA7

Shown below is the maximum screw-in depth of the tapping screws used for mounting the base. Be careful not to allow the tip of the bolt to project.

Type Tapped hole diameter Maximum screw-in depth

RA7 M5 15 mm

(10) Using T-grooves and square nuts

Applicable models: RA5C, RA5R, F5D The RA5 and F5 types have T-grooves. Insert square nuts in these T-grooves and install the actuator to the frame.

T-grooves

Square nuts

(11) Using feet

Applicable models: RA5, RA5R, RA7 (excluding flat types)

[1] On the RA7 type, attac h feet using th e tap pe d

mounting holes at the back.

[2] On the RA5 type, attach feet using square nuts

inserted into the T-grooves.

Foot

Install the feet to the frame using bolts.

(12) Using tapped holes on the reference surface

Applicable models: RA5, RA5R, RA7 (excluding flat types and guide types)

Type Tapped hole diameter Effective thread depth

RA5 / RA5R M6 12 mm

RA7 M5 15 mm

Foot

8. Wiring Cable

• In an application where the cable cannot be anchored, try to place the cable so that it sags only under its own weight or use self-standing type cable as large radial wire duct to limit the load on the cable.

• Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length.

• The cables supplied with the actuator offer excellent flexibility, but they are not robot cables. If the cables are to be stored in a movable cable duct (cable bearer, etc.), use robot cables.

For cable modification, please contact your IAI sales representative.

9. Connecting the Air Tube of the RCS2W Dustproof/Splash-proof

Type

Intake/exhaust port

Install the air tube (outer diameter: 10 mm, inner diameter: 6.5 mm) on the intake/exhaust port and guide the air tube to a location where the external environment assures the tube will not come in contact with water.

(Applicable tube) Shown below is a representative m odel of air tube tha t ca n be inst alled on the RC S2W :

• TU1065: Polyurethane tube (Manufacturer: SMC)

Caution: The air tube should not be more than 3 m long.

10. Maximum Speed

The maximum speed of the actuator is limited to prevent resonance of the ball screw shaft and also in consideration of the restrictions on motor speed. Observe the maximum speed limits specified below.

Maximum speed limits

Type

RA4 type

RA5 type

RA7AD type

RA7BD type

F5D type

Caution: If the maximum speed limit is exceeded, noise may increase or vibration may occur

due to resonance of the ball screw shaft, in which case the serv ic e l ife of th e actua tor may be significantly reduced. If multiple actuators are used together, with ea ch actu ato r op er at ing inde pe nd e n tly , create programs where each actuator does not exceed the applicable maximum speed (see the table above). If operations of multiple actuators are synchronized, programs should be based on the lowest maximum speed among the combined actuators. Create appropriate program by check i ng the maxim u m speed of ea ch actu ato r.

Lead

3 mm 150 mm/sec 6 mm 300 mm/sec

12 mm 600 mm/sec

4 mm 200 mm/sec 188 mm/sec 8 mm 400 mm/sec 377 mm/sec

16 mm 800 mm/sec 755 mm/sec

3 mm 150 mm/sec 125 mm/sec 6 mm 300 mm/sec 250 mm/sec

12 mm 600 mm/sec 505 mm/sec

4 mm 200 mm/sec 8 mm 400 mm/sec

16 mm 800 mm/sec

3 mm 200 mm/sec 6 mm 400 mm/sec

12 mm 800 mm/sec

Stroke

50 to 250 mm 300 mm

Maximum speed

11. Load on the Actuator

• The actual load should not exceed the value specified in the catalog.

• Be sure to align the shaft center of the rod and the moving direction of the load.

• Lateral load may cause damage or breakdown of the actuator.

• If the rod may receive lateral load, provide a guide or other appropriate mechanism to support the

actuator in the moving direction of the load.

• Do not allow the rod (slide shaft) to receive rotational torque. * Doing so may damage the internal parts.

Tighten the nut at the tip of the rod, while securely holding the rod using a wrench of size 17 (RA4) or 22 (RA5).

12. Actuators with a Switch (Optional)

On actuators with a switch, the switch is stored inside the actuator body on the motor side. Do not increase the homing speed beyond the default factory setting. If the homing speed is increased beyond the default, the switch may be damaged.

13. High Acceleration/Deceleration Option

13.1 Applicable Actuator Models

Actuators that support high acceleration/deceleration are indicated by an option code at the end of the model name. Other applicable options are the same as those available with conventional models.

Series Model

RA4C N

RGS4C 16 P

RCS2 -

HA: High acceleration/deceleration option (The actuator has a rated acceleration/deceleration of (Blank): Conv en tional sp ec ifica tio n (The actu at or h as a rated ac ce lera tion /d ec ele ration of 0.3 G, and is (Example) RCS2-RA4C-I-20-10-50-T1-S-HA

RGD4C 20 12 S

RA5C 30 8 M RGS5C 60 6 X RGD5C

1 G and is combined with a controller of high acceleration/deceleration specification.) combined with a conventional controller.)

RCS2-RA4C-I-20-10-50-T1-S xxxxxxxxxxxxx Conventional specification

Encoder

type

- IA -

13.2 Specifications of High Acceleration/Deceleration Actuators

Model

RA4C RGS4C RGD4C

RA5C RGS5C RGD5C

Motor output

(W)

100

Lead

(mm)

12 4 1.5 28.3 1.0

6 9 3 56.6 1.0

12 4 1 28.3 1.0

6 9 2.5 56.6 1.0

12 4 1 28.3 1.0

6 9 2.5 56.6 1.0

16 15 3.5 105.8 1.0

8 30 9 212.7 1.0

16 15 2.8 105.8 1.0

8 30 8.3 212.7 1.0

16 15 2.8 105.8 1.0

8 30 8.3 212.7 1.0

Motor

output

Maximum loading capacity

Horizontal (kg) Vertical (kg)

Lead Stroke

100

- 50~800 -

High acceleration/deceleration type

Applicable

controller

Rated

thrust (N)

Cable length

T1 T2

R

acceleration/deceleration (G)

Options

Rated

Blank

13.3 Notes

Take note of the following points if you are using a high acceleration/deceleration type: (1) Keep the duty within 50%. If the duty exceeds 50%, an overload error may occur. (2) The maximum loading capacity follows the applicable value specified in the table under

“Specifications of High acceleration/Deceleration Actuators” regardless of the acceleration setting.

(3) Refer to p. 29 for the maximum speed.

13.4 Applicable Controller Models (SCON, SSEL, X-SEL)

The following code is appended after the enc ode r type : HA: High acceleration/deceleration specification (Blank): Conventional specification (Examples) [1] High acceleration/deceleration specification

SCON-C-20IHA

[2] Conventional specification

SCON-C-20I-NP-2-0

The applicable controllers vary depending on the actuator specification. Check the model of the actuator you will be using.

-NP-2-0

14. Maintenance

14.1 Maintenance Schedule

Perform maintenance work acc ording to the schedule below. The schedule is set assuming eight hours of operation a day. When the operation time is long such as

24-hour operation, shorten the maintenance intervals as needed.

Visual inspection Grease supply

Start of operation

After 1 month of operation

After 3 months of operation

Every 3 months thereafter

After 3 years of operation, or upon

reaching 5,000 km in traveled distance

Every year thereafter

*1 Apply grease to the sliding surface of the rod at the startup check if grease has been consumed, or

every three months. For the RCS2W dustproof/splash-proof type, apply grease when the bellows is changed.

14.2 Visual Inspection of the Machine Exterior

Check the following items visually.

Body Loose mounting bolts? Cables Damage to cables or connection to connector box? General Unusual noise or vibrations?

14.3 Cleaning

• Clean the exterior as needed.

• Wipe off dirt with a soft cloth.

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

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

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

{ { { {

{ {

{ (Sliding surface of the rod) *1 { (Sliding surface of the rod) *1

14.4 Applying Grease to the Sliding Surface of the Rod

(1) Applicable grease

Kyodo Yushi Multemp LRL3

Warning: Never use any fluorine-based grease. It will cause a chemical reaction when

mixed with a lithium-based grease and may cause damage to the actuator.

(2) How to apply grease

Apply grease over the entire surface of the rod.

14.5 Reduction Belt [Motor Reversing Type]

14.5.1 Inspecting the Belt

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

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

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

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

• The belt has broken.

14.5.2 Applicable Belt

• RA4R - 60S2M152R Rubber, cleanroom type (Bando Chemical Industries) 6 mm wide

• RA5R - 100S3M219R Rubber, cleanroom type (Bando Chemical Industries) 10 mm wide

14.5.3 Adjusting the Belt Tension (RA4R Type)

Remove the pulley case cover and loosen the four motor-unit affixing bolts. Pass a looped string (or long tie-band) around the motor unit, and pull the string to the specified tension using a tension gauge. In this condition, uniformly tighten the motor-unit affixing bolts.

[Recommended tightening torque of adjustment bolts] 162 N-cm (16.5 kgf-cm)

Tension: 2.5 kgf

Motor-unit affixing bolts

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

(Use an Allen wrench of 2.5 mm across flats.)

14.5.4 Adjusting the Belt Tension (RA5R)

Tension: 6 ± 0.2 kgf

Motor-unit affixing bolts (Use an Allen wrench of 3 mm across flats.)

14.5.5 Replacing the Belt of the Motor Reversing Type: RA4R Type

[Items Required for Replacement]

• Replacement belt RA4R --- 60S2M152R Rubber, cleanroom type (Bando Chemical Industries) 6 mm wide

• Allen wrenches

• Tension gauge (capable of tensioning to 7 kgf or greater)

• Strong string, looped (or long tie-band)

• Scale

• Oil-based marker pen

• PC or teaching pendant

[Overview of Replacement]

1) Move the rod to a position where Z phase turns on (home position) (2 mm from the mechanical end). In this position, loosen the motor-unit affixing bolts and replac e the belt.

2) Restore the home position. Affix the rod at a position 2 mm from the mechanical end on the home side, pass the belt, and adjust the belt to the specified tension.

3) Perform homing using a PC or teaching pendant and check for deviation from the initial home position. If there is a deviation, adjust the home offset SSEL or X-SEL controller, adjust the home preset

Home position

Z phase ON position

1 mm

The countermark on the motor aligns with this position.

Set by the home offset parameter (SCON) or home preset parameter (SSEL, X-SEL). (The above value indicates the factory setting.)

if you are using an SCON controller. If you are using an

Mechanical end

Approx. 2 mm

[Procedure]

1) Remove the pulley case cover using two Allen wrenches, one of 2 mm across flats and the other of 3 mm across flats.

M4 hexagon socket head screws

M3 hexagon socket head screws

2) Move the rod to a position wh ere Z phase turns on (home position). This corresponds to a position where the rod projects 2 mm from the mechanical end. Apply countermarks in this position.

Cause the rod to project 2 mm from the mechanical end.

2 mm

Apply countermarks once the rod has projected 2 mm from the mechanical end.

Warning: If the actuator is installed vertically, move it after turning on the controller pow er

and forcibly releasing the brake. At this time, beware of danger as the actuator may drop suddenly. Always provide a support to brace the actuator hand to prevent sudden drop, so as not to pinch fingers or damage the load.

3) Loosen the motor-unit affixing bolts using an Allen wrench of 2.5 mm across flats. Slide the motor, and loosen and remove the belt.

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

4) Check the following points before restoring the home position:

• The motor side should be aligned with the initial countermark. If the position is offset, adjust it to

achieve proper alignment.

• The ball-screw side should be at a position where the rod projects 2 mm from the mechanical end. After the check, attach a new belt while holding the pulleys on both sides in position.

Initial countermark position

Corresponding to a position where the rod projects 2 mm from the mechanical end

Motor side

Ball-screw side

5) Adjust the belt tension. Pass a looped strong string (or long tie-band) around the motor cover and pull it with a tension gauge to the specified tension. In this condition, uniformly tighten the motor-unit affixing bolts. [Recommended tightening torque for adjustment bolts] 162 N-cm (16.5 kgf-cm)

Tension: 2.5 kgf

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

6) Install the pulley case cover using two Allen wrenches, one of 2 mm across flats and the other of 3 mm across flats.

M4 hexagon socket head screws

M3 hexagon socket head screws

7) Connect a PC or teaching pendant to the controller to perform homing. (If the actuator is of absolute encoder specification, an absolute reset must be performed.) Check for deviation from the initial home position. If there is a deviation, adjust parameter No. 22, “Home offset you are using an SSEL or X-SEL controller, adjust axis-specific parameter No. 12, “Home preset

” if you are using an SCON co ntroller. If

.” If your controller is of absolute encoder specification, perform homing after changing the parameter, and then perform an absolute reset.

14.5.6 Replacing the Belt of the Motor Reversing Type: RA5R Type

[Items Required for Replacement]

• Replacement belt RA5R ---100S3M219R Rubber, cleanroom type (Bando Chemical Industries) 10 mm wide

• Allen wrenches

• Tension gauge (capable of tensioning to 8 kgf or greater)

• Strong string, looped (or long tie-band)

• Scale

• Oil-based marker pen

• PC or teaching pendant

[Overview of Replacement]

1) Move the rod to a position where Z phase turns on (home position) (2 mm from the mechanical end). In this position, loosen the motor-unit affixing bolts and replac e the belt.

2) Restore the home position. Affix the rod at a position 4 mm from the mechanical end on the home side, pass the belt, and adjust the belt to the specified tension.

Home position

Z phase ON position

2 mm

The countermark on the motor aligns with this position.

Set by the home offset parameter (SCON) or home preset parameter (SSEL, X-SEL). (The above value indicates the factory setting.)

if you are using an SCON controller. If you are using an

Mechanical end

2 mm

[Procedure]

1) Move the slider from the home position toward the mechanical end and check the rotating direction of the motor shaft. (If the actuator has its home located on the opposite side to the standard specification, this check is always required because the motor shaft rotates in the different direction.)

• Remove the pulley case cover.

(Remove the three thin-head screws using an Allen wrench of 2.5 mm across flats.)

Check the rotating direction of the motor shaft.

2) Loosen the four tension adjustment bolts to slacken the belt.

3) Remove the belt from the pulleys.

(Allen wrench of 3 mm across flats)

3) Make the following adjustment to rest ore the home position:

• Move the slider to the mechanical end on the home side and keep it in contact with the mechanical

end.

• Turn the motor shaft by the specified amount from the countermark position toward the return-to-

mechanical-end direction (the direction checked at the beginning).

Type

RA5R-16

RA5R-8 RA5R-4

Amount returned from the

countermark position

67.5° 135° 230°

4) Adjust the belt tension. Pass a looped strong string (or long tie-band) around the motor cover and pull it with a tension gauge to the specified tension. In this condition, uniformly tighten the motor-unit affixing bolts. Recommended tightening torque for adjustment bolts: (M5) 763 N-cm (78 kgf-cm)

Caution: After tightening the bolts to the above torque, tighten them slightly further by making sure

that both pulleys do not move.

Tension: 6 ± 0.2 kgf

5) Install the pulley cover. Tighten the three hexagon socket head bolts (M3x22) using an Allen wrench of 2.5 mm across flats.

6) Perform homing using a PC or teaching pendant. (If the actuator is of absolute encoder specification, an absolute reset must be performed). Check for deviation from the initial home position. If there is a deviation, adjust parameter No. 22, “Home offset

” if you are using an SCON co ntroller. If you are using an SSEL or X-SEL controller, adjust axis-specific parameter No. 12, “Home preset your controller is of absolute encoder specification, perform homing after changing the parameter, and then perform an absolute reset.

.” If

14.6 Replacing the Motor

14.6.1 Replacing the Motor of the Motor Straight Type (Coupling Type): RA4C Type

[Items Required for Replacement]

• Replacement motor unit • Coupling (with screws)

• Allen wrenches

• Scale • Oil-based marker pen

• Grease

Idemitsu Kosan Daphne Eponex Grease No.2

• PC or teaching pendant

[Overview of Replacement]

1) Move the rod to a position where Z phase turns on (home position) (2 mm from the mechanical end). In this position, replace the motor.

2) Perform homing using a PC or teaching pendant and check for deviation from the initial home position. If there is a deviation, adjust the home offset SSEL or X-SEL controller, adjust the home preset

if you are using an SCON controller. If you are using an

Home position

Z phase ON position

Mechanical end

1 mm

Approx. 2 mm

The countermark on the motor aligns with this position.

Set by the home offset parameter (SCON) or home preset parameter (SSEL, X-SEL). (The above value indicates the factory setting.)

Replacement motor unit

Coupling (with screws)

[Procedure]

1) Move the rod to a position wh ere Z phase turns on (home position). This corresponds to a position where the rod projects 2 mm from the mechanical end. Apply countermarks in this position.

Cause the rod to project 2 mm from the mechanical end.

2 mm

Apply countermarks once the rod has projected 2 mm from the mechanical end.

Warning: If the actuator is installed vertically, move it after turning on the controller power

2) Using an Allen wench of 2 mm across flats, remove the two motor-unit affixing bolts on the right and left.

2 affixing bolts on the motor-end cap (right and left) (hexagon socket head setscrews)

3) Pull out the motor unit. Before pulling out the motor unit, apply a countermark on the cylinder tube at a position corresponding to the tab on the motor unit, so that the motor unit and cylinder can be aligned in the correct position later on.

Tab on the motor unit

Apply a countermark at a position corresponding to the tab on the motor unit.

4) Apply grease on the actuator coupling.

Apply grease on the inside of the coupling.

5) Align the tab on the replacement motor unit with the countermark on the cylinder. With the motor unit and cylinder aligned properly, insert the coupling into the replacement motor unit by aligning the orientation of this coupling with that of the actuator coupling (adjusted to a position corresponding to a rod projection of 2 mm from the mechanical end). Apply countermarks to identify the current motor position (phase Z position) and coupling.

Align the tab on the replacement motor unit with the countermark on the cylinder.

Position the couplings.

Coupling

After the coupling has been inserted, apply countermarks on the replacement motor unit and coupling.

Replacement motor unit

6) Turn the coupling and motor shaft simultaneously until a setscrew on the coupling is seen through the hole. Thereafter, tighten the hexagon socket head sets cre w using an Allen wrench of 2 mm across flats. Similarly, turn the coupling and motor shaft simultaneously until the other screw is seen through the hole, and tighten the setscrew.

Coupling setscrew hole

Turn the coupling and motor shaft simultaneously until a setscrew on the coupling is seen through the hole. Thereafter, tighten the hexagon socket head setscrew using an Allen wrench of 2 mm across flats.

7) Return the coupling in the replacement motor unit to the initial motor position (Z phase position). Align the tab on the replacement motor unit with the countermark on the cylinder. With the motor unit and cylinder positioned this way, confirm that the orientation of the actuator coupling (adjusted to a position corresponding to a rod projection of 2 mm from the mechanical end) corresponds to the position of the coupling in the replacement motor unit.

Coupling

Apply countermarks on the replacement motor unit and coupling.

Replacement motor unit

Align the tab on the replacement motor unit with the countermark on the cylinder.

Confirm that the coupling positions correspond.

8) Carefully insert the replacement motor unit into the cylinder by ensuring that the couplings do not lose

their alignment.

9) Using an Allen wench of 2 mm across flats, tighten the two motor-unit affixing bolts on the right and

left.

2 affixing bolts on the motor-end cap (right and left) (hexagon socket head setscrews)

10) Connect a PC or teaching pendant to the controller to perform homing. (If the actuator is of absolute

encoder specification, an absolute reset must be performed). Check for deviation from the initial home position. If there is a deviation, adjust parameter No. 22, “Home offset you are using an SSEL or X-SEL controller, adjust axis-specific parameter No. 12, “Home preset

” if you are using an SCON controller. If

.” If your controller is of absolute encoder specification, perform homing after changing the parameter, and then perform an absolute reset.

14.6.2 Replacing the Motor of the Motor Reversing Type: RA4R Type

[Items Required for Replacement]

• Replacement motor unit • Allen wrenches

• Tension gauge (capable of tensioning to 7 kgf or greater)

• Strong string, looped (or long tie-band)

• Scale • Oil-based marker pen

• PC or teaching pendant

[Overview of Replacement]

1) Loosen the motor-unit affixing bolts to remo ve the belt, an d repla ce th e moto r.

2) Restore the home position. Affix the rod at a position 2 mm from the mechanical end on the home side, pass the belt, and adjust the belt to the specified tension.

if you are using an SCON controller. If you are using an

Home position

Z phase ON position

Mechanical end

1 mm

Approx. 2 mm

The countermark on the motor aligns with this position.

Set by the home offset parameter (SCON) or home preset parameter (SSEL, X-SEL). (The above value indicates the factory setting.)

Replacement motor unit

[Procedure]

1) Remove the pulley case cover using two Allen wrenches, one of 2 mm across flats and the other of 3 mm across flats.

M3 hexagon socket head screws

2) Loosen the motor-unit affixing bolts using an Allen wrench of 2.5 mm across flats. Slide the motor, and loosen and remove the belt. After the belt has been removed, remove the motor-unit affixing bolts.

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

M4 hexagon socket head screws

3) Take out the motor.

4) Install the replacement motor. Lo osely tighten the motor-unit af fixing bolts.

Replacement motor

5) Move the rod to a position wh ere Z phase turns on (home position). This corresponds to a position where the rod projects 2 mm from the mechanical end. Apply countermarks in this position.

Cause the rod to project 2 mm from the mechanical e nd.

2 mm

Apply countermarks once the rod has projected 2 mm from the mechanical end.

Warning: If the actuator is installed vertically, move it after turning on the controller pow er

6) Check the following points before restoring the home position:

• The motor side should be aligned with the initial countermark. If the position is offset, adjust it to achieve proper alignment.

• The ball-screw side should be at a position where the rod projects 2 mm from the mechanical end.

After the check, attach a new belt while holding the pulleys on both sides in position.

Initial countermark position

Corresponding to a position where the rod projects 2 mm from the mechanical end

Motor side Ball-screw side

7) Adjust the belt tension. Pass a looped strong string (or long tie-band) around the motor cover and pull it with a tension gauge to the specified tension. In this condition, uniformly tighten the motor-unit affixing bolts. [Recommended tightening torque for adjustment bolts] 162 N-cm (16.5 kgf-cm)

Tension: 2.5 kgf

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

(Use an Allen wrench of 2.5 mm across flats.)

Motor-unit affixing bolts

8) Remove the pulley case cover using two Allen wrenches, one of 2 mm across flats and the other of 3 mm across flats.

9) Connect a PC or teaching pendant to the controller to perform homing. (If the actuator is of absolute encoder specification, an absolute reset must be performed.) Check for deviation from the initial home position. If there is a deviation, adjust parameter No. 22, “Home offset you are using an SSEL or X-SEL controller, adjust axis-specific parameter No. 12, “Home preset your controller is of absolute encoder specification, perform homing after changing the parameter, and then perform an absolute reset.

M3 hexagon socket head screws

” if you are using an SCON controller. If

M4 hexagon socket head screws

.” If

14.6.3 Replacing the Motor of the Motor Reversing Type: RA5R Type

[Items Required for Replacement]

• Replacement motor with pulleys (See the photograph to the right.) (Confirm that the motor has countermarks.)

• PC or teaching pendant

• Allen wrenches

• Tension gauge (capable of tensioning to 8 kgf or greater)

• Strong string, looped (or long tie-band)

• Scale

• Oil-based marker pen

[Overview of Replacement]

1) Move the rod to a position where Z phase turns on (home position) (2 mm from the mechanical end). In this position, replace the motor.

2) Restore the home position. Affix the rod at a position 4 mm from the mechanical end on the home side, pass the belt, and adjust the belt to the specified tension.

Home position

Z phase ON position

2 mm

The countermark on the motor aligns with this position.

Set by the home offset parameter (SCON) or home preset parameter (SSEL, X-SEL). (The above value indicates the factory setting.)

if you are using an SCON controller. If you are using an

Mechanical end

2 mm

[Procedure]

• Remove the pulley case cover.

(Remove the three thin-head screws using an Allen wrench of 2.5 mm across flats.)

Check the rotating direction of the motor shaft.

2) Loosen the four tension adjustment bolts to slacken the belt.

3) Remove the belt from the pulleys.

(Allen wrench of 3 mm across flats)

3) Take out the motor. Remove the four hexagon socket head bolts using an Allen wrench of 3 mm across flats.

4) Install the new motor. Uniformly tighten the four hexagon socket head bolts (M4x15) using the Allen wrench of 3 mm across flats.

Recommended tightening torque: 176 N-cm (18 kgf-cm)

5) Make the following adjustment to rest ore the home position:

• Move the slider to the mechanical end on the home side and keep it in contact with the mechanical

end.

• Turn the motor shaft by the specified amount from the countermark position toward the return-to-

mechanical-end direction (the direction checked at the beginning).

Type

RA5R-16

RA5R-8 RA5R-4

Amount returned from the

countermark position

67.5° 135° 230°

6) Adjust the belt tension. Pass a looped strong string (or long tie-band) around the motor cover and pull it with a tension gauge to the specified tension. In this condition, uniformly tighten the motor-unit affixing bolts. Recommended tightening torque for adjustment bolts: (M5) 763 N-cm (78 kgf-cm)

Caution: After tightening the bolts to the above torque, tighten them slightly further by making sure

that both pulleys do not move.

Tension: 6 ± 0.2 kgf

7) Install the pulley cover. Tighten the three hexagon socket head bolts (M3x22) using an Allen wrench of 2.5 mm across flats.

8) Perform homing using a PC or teaching pendant. (If the actuator is of absolute encoder specification, an absolute reset must be performed). Check for deviation from the initial home position. If there is a deviation, adjust parameter No. 22, “Home offset

.” If

14.7 Replacing the Be ll ows of t h e RCS2 W D ustproof/Splash-proof Type

[Items Required for Replacement]

• Replacement bellows unit : RA4 --- JB-RA4- (stroke)

• Phillips screwdriver

• Torque driver

• Grease

Kyodo Yushi Multemp LRL3

[Procedure]

1) Loosen the front and rear metal fittings affixing the bellows and remove the bellows.

Loosening of front metal fitting Loosening of rear metal fitting

Removal of bellows Bellows has been removed

Bellows

2) Apply grease evenly over the entire cylinder surface.

3) Install a metal fitting on the bellows.

Bellows

Apply grease evenly over the entire surface.

Install a metal fitting on the bellows.

4) Install the replacement (new) bellows and tighten the screws of the front and rear metal fittings

affixing the bellows. Tighten the screws to the specified torque using a torque driver.

Installation of bellows

Tightening of rear metal fitting Tightening of front metal fitting

Tightening torque: 2 N-m

15. Cable Drawings

[1] Motor cable/robot motor cable

Model: CB-RCC-MA /CB-RCC-MA -RB

(16)

(41)

(Front view) (Front view)

(20)

Controller end

Wire

0.75 sq

Signal

U V

(9 ∅)

No.

1 2 3

(21)

Signal

No.

1 2 3

U V

(21) (10)

Actuator end

Wire

0.75 sq

(crimped)

(18)

[2] Encoder cable/robot encoder cable (X-SEL-J/K)

(SCON, SSEL, X-SEL-P/Q) Model: CB-RCBC-PA /CB- RCBC-PA 

(16)

(57)

(33)

(Front view)

Controller end

(8 ∅)

Wire

0.15 sq

(crimped)

Clamp the shield to the hood.

Ground and shielded braided wires

Signal

/U /U

B/V

Z/W

SD SD

BAT + BAT -

VCC GND

BK BK +

No.

2 3

7 8

(36)

Actuator end

Signal

No.

2 3 4

6 7

9 10 11 12

13 14 15 16 17 18

B/V B/V

Z/W Z/W

FG SD

BAT +

BAT -

VCC GND

BK -

BK +

(15)

(14)

1.10

(Front view)

9.18

Wire

0.15 sq

(crimped)

(25)

[3] Encoder cable/robot encoder cable

Model: CB-RCS2-PA /CB- X2-PA -RB

(13)

(41) (14)

(37)

(Front view)

14 26

Controller end

Wire

Color

Gray/white

Brown/white

AWG26

(soldered)

Clamp the shield to the hood.

Pink

Purple

Blue/red

Orange/white Orange/white

Green/white

Blue

Orange

Black

Yellow

Green Brown

Gray

Red

Signal

E24V

CLEEP

RSV

A + A B +

B Z +

Z SRD + SRD BAT + BAT VCC GND BKR BKR +

Note 3

No.

10 11 12 13 26 25 24

9 18 19

1 2

3 4 5 6 7 8

15 16

Note 4

Ground and shielded braided wires

Note 1

(15)

1.10

(25)

9.18

(Front view)

Wire

AWG26

(crimped)

Note 2

No.

2 3 4 5 6 7 8

12 13

16 17 18

Actuator end

Signal

B B

Green/white

Brown/white

LS +

FG SD

SD BAT + BAT VCC GND

Gray/white

LS -

BK -

BK +

Color

Pink

Purple

White White

Blue/red

Ground

Blue

Orange

Black

Yellow

Green

Brown

Gray

Red

MEMO

Catalog No.: MJ3656-3A

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

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

Chicago Office: 1261 Hamilton Parkway, Itasca, IL 60143

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

Atlanta Office: 1220-E Kenneston Circle, Marietta, GA 30066

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

Website: www.intelligentactuator.com

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

TEL 06196-88950 FAX 06196-889524

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