ERC Actuator with Integrated Controller Operation Manual Seventh Edition
Please Read Before Use Thank you for purchasing our product. This Operation Manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The CD that comes with the product contains operation manuals for IAI products.
CAUTION 1. When Using Multiple 24-V Power Supplies If multiple 24-V power supplies are used, be sure to adjust 0 V to the same level on all units. If 0 V varies among the power supplies, the controller board, SIO converter or other hardware may be damaged.
CAUTION 2. Basic Parameter Settings When the power is input for the first time, at least the two parameters specified below must be set in accordance with the intended application. If these parameters are not set properly, the ERC will not function correctly. So, pay due attention to ensure the parameters are set properly. For details on the setting method, refer to the “parameter settings” of the PC or teaching pendant.
CAUTION 3. Recommendation for Backing up Latest Data The controller part of this actuator uses nonvolatile memory to store the position table and parameters. Normally the memory will retain the stored data even after the power is disconnected. However, the data may be lost if the nonvolatile memory becomes faulty.
Table of Contents Safety Guide ........................................................................................................ 1 1. Overview......................................................................................................... 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Introduction .............................................................................................................................................1 Meaning of the Model Name .....................................
Pause (*STP).................................................................................................................................. 27 3.2.3 Details of Output Signals .......................................................................................................... 28 Completion of each position (PE0 to PE2) ..................................................................................... 28 Alarm (*ALM) ...........................................................................
5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 Push & Hold Mode Push = Other than 0................................................................................... 68 Speed Change during Movement ............................................................................................. 70 Operation at Different Acceleration and Deceleration Settings ................................................ 70 Pause ..........................................................................................................
Movement command type ............................................................................................................ 107 Pause input disable selection ....................................................................................................... 108 Serial communication speed ........................................................................................................ 108 Minimum delay time for slave transmitter activation ..........................................
Safety Guide This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property damage. Be sure to read this section before using your product. Regulations and Standards Governing Industrial Robots Safety measures on mechanical devices are generally classified into four categories under the International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows: Safety measures Inherent safety design Protective guards --- Safety fence, etc.
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health Work area Outside movement range Inside movement range Pre-2 Work condition During automatic operation Cutoff of drive source Measure Signs for starting operation Not cut off Installation of railings, enclosures, etc. Cut off (including Sign, etc., indicating that work is stopping of operation) in progress Preparation of work rules Measures to enable immediate During stopping of operation teaching, etc. Sign, etc.
Applicable Modes of IAI’s Industrial Robot Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No.
Notes on Safety of Our Products Common items you should note when performing each task on any IAI robot are explained below. No. Task 1 Model selection 2 3 4 Note This product is not planned or designed for uses requiring high degrees of safety. Accordingly, it cannot be used to sustain or support life and must not be used in the following applications: [1]Medical devices relating to maintenance, management, etc.
No. Task 4 Installation/ startup 5 Teaching Note (2) Wiring the cables Use IAI’s genuine cables to connect the actuator and controller or connect a teaching tool, etc. Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place heavy articles on top. Current leak or poor electrical continuity may occur, resulting in fire, electric shock or malfunction. Wire the product correctly after turning off the power.
No. Task 5 Teaching 6 Confirmation operation * 7 Automatic operation 8 Maintenance/ inspection 9 Modification * 10 Disposal Pre-6 Note When releasing the brake of the vertically installed actuator, be careful not to let the actuator drop due to its dead weight, causing pinched hands or damaged load, etc. Safety fences --- Indicate the movement range if safety fences are not provided.
Indication of Cautionary Information The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and “Note,” as specified below. Level Degree of danger/loss Symbol Danger Failure to observe the instruction will result in an imminent danger leading to death or serious injury. Danger Warning Failure to observe the instruction may result in death or serious injury. Warning Caution Failure to observe the instruction may result in injury or property damage.
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1. 1.1 Overview Introduction Thank you for purchasing the Easy All-in-One Robo Cylinder (hereinafter referred to as “ERC”). This manual explains the features and operating procedures of the product. If not used or handled properly, even a brilliant product cannot fully demonstrate its function or may cause an unexpected breakdown or end its life prematurely. Please read this manual carefully and handle the product with utmost care while ensuring its correct operation.
1.2 Meaning of the Model Name ERC-RA54-I-PM-12-300-S-NM Slider type ・SA6 ・SA7 Rod type ・RA54 ・RA64 ・RA54GS ・RA64GS ・RA54GD ・RA64GD I: Incremental Blank: No option B: With brake NM: Reversed-home specification FT: Foot bracket (Specified only for rod types.
1.3 Specifications Stroke (mm) and maximum speed (mm/sec) (Note 1) Load capacity (Note 2) Horizontal Vertical Rated acceleration Horizontal Vertical Rod type Slider type Model (Note 1) (Note 2) The figures in blank bands indicate the maximum speeds for respective strokes. The maximum speeds during vertical operation are shown in parentheses. The load capacity is based on operation at the rated acceleration.
1.3.1 Correlation Diagrams of Speed and Load Capacity – Slider Type Vertical installation Load capacity (kg) Load capacity (kg) High-speed type Horizontal installation Speed (mm/sec) Load capacity (kg) Load capacity (kg) Medium-speed type Speed (mm/sec) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) (Note) In the above graphs, the number after each type name indicates the lead.
1.3.2 Correlation Diagrams of Speed and Load Capacity – Rod Type Vertical installation Load capacity (kg) Load capacity (kg) High-speed type Horizontal installation Speed (mm/sec) Load capacity (kg) Load capacity (kg) Medium-speed type Speed (mm/sec) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) (Note) In the above graphs, the number after each type name indicates the lead.
Load Applied to the Actuator (1) Slider type Keep the load applied to the slider below the value stated in the applicable specification item. In particular, pay attention to the moment applied to the slider, allowable overhung length and load capacity. If the slider is used in an overhung application with the load extending in the Y-axis direction, keep moments Ma and Mc to one-half the rated moment or less to prevent the base from deforming.
1.4 Safety Precautions Read the following information carefully and provide safety measures with due consideration. This 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.
1.5 Warranty Period and Scope of Warranty The ERC 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.
1.6 1.6.1 Transportation and Handling Handling before Unpacking Exercise due caution when transporting or handling the box containing the actuator, by not applying impact on the box as a result of collision or dropping. If the box is heavy, one person should not carry it by himself. Place the box in a level surface. Do not step on the box. Do not place on the box any heavy object that may cause the box to deform or other object with a section where loads will concentrate. 1.6.
1.7 Installation Environment and Noise Elimination Pay due attention to the installation environment of the controller. 1.7.1 Installation Environment The installation environment must satisfy the following conditions: No. Use environment/condition [1] Not exposed to direct sunlight. [2] The actuator is not subject to irradiated heat from a large heat source, such as a heat treatment furnace. [3] Ambient temperature of 0 to 40C. [4] Humidity of 85% or less without condensation.
1.7.3 Power Supply The control/motor-drive power supply specification is 24 VDC 10% (2 A max). 1.7.4 Noise Elimination This section explains how to eliminate noise in the use of the controller. (1) Wiring and power supply [1] Provide a dedicated class D grounding using a wire with a size of 0.75 mm2 or larger. Actuator with integrated controller Class D grounding [2] Other equipment Good Actuator with integrated controller Other equipment Avoid this grounding method.
(2) Noise sources and elimination Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular concern when building a system. Noise from these sources can be eliminated by implementing the measures specified below. [1] AC solenoid valves, magnet switches and relays Measure: Install a surge absorber in parallel with the coil. Surge absorber [2] Point Install a surge absorber to each coil over a minimum wiring length.
1.8 Cabling The standard relay cables have excellent flexibility to withstand fatigue from flexural loads, but they are not robot cables. Therefore, avoid storing the standard relay cables in movable cable ducts laid at a small radius. If they must be stored in movable cable ducts, use robot cables.
Prohibited Handling of Cables When designing an application system using this actuator, 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. Steel band (piano wire) Bundle loosely. 2. Do not let the cable bend, kink or twist. 3.
7. Notes on use of cable tracks The supplied cable is not a robot cable. Accordingly, never store this cable in a cable track. For the extension cable, be sure to use a robot cable. Bending radius r Use a cable track at a bending radius r of at least 50 mm. 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).
2. Installation 2.1 Name of Each Part 2.1.1 Slider Type (SA6/SA7) Screw cover Coupling bolt Right Non-motor end Motor end Side cover Left Top Front bracket Rear bracket LED Motor bracket Rear cover Slider Motor cover Base Bottom Cable Connection port for teaching pendant or PC (The arrow on the connector should face down.) 2.1.
2.1.3 (1) Rod Type with a Single Guide (RA54GS/RA64GS) Coupling bolt LED Right Motor end Non-motor end Left Top Guide bracket Guide bearing Guide rod Rod Bottom Rear bracket Motor bracket Frame Rear cover Motor cover Cable Connection port for teaching pendant or PC (The arrow on the connector should face down.) 2.1.
2.2 2.2.1 Installation Slider Type Installing the actuator The actuator-mounting surface must be a machined surface or have an equivalent flatness. The side and bottom faces of the actuator base are parallel with the guides. If high slide accuracy is required, install the actuator by using these surfaces as references. Install the actuator in the mounting holes provided in the base. Secure the actuator in place using M4 hex cap bolts.
2.2.2 Rod Type A rod-type actuator can be installed in the following two ways: Affixing with a flange Install the actuator by tightening from the motor end side with hex cap bolts using the holes provided in the flange. Caution: If the actuator is installed horizontally, exercise caution not to let the actuator receive excessive forces. Hex cap bolt Hole in flange Flange tightening bolts Model Nominal thread size Tightening torque RA54 M5 3.4 Nm (0.35 kgfm) RA64 M6 5.4 Nm (0.
Affixing with foot brackets (optional) If optional foot brackets are used, install the foot brackets using hex cap bolts. Foot-bracket tightening bolts Model RA54 RA54GS RA54GD RA64 RA64GS RA64GD 20 Nominal thread size Tightening torque M6 5.4 Nm (0.55 kgfm) M8 11.5 Nm (1.
2.2.3 Installing the Load Slider Type Four tapped holes are provided in the slider, so affix the load using these holes (indicated by arrows in the figure shown to the left). Type SA6, SA7 Nominal thread size M5 Slider mounting hole M5, depth 9 mm Tightening torque Bolt bearing surface: steel Bolt bearing surface: aluminum 7.3 Nm (0.74 kgfm) 3.4 Nm (0.35 kgfm) The affixing method of the load shall conform to the installation method of the actuator.
Rod Type A bolt is attached on the rod end bracket, so use this bolt to affix the load. (Use the supplied nut, if necessary.) Rod end bracket Model RA54 RA64 Note) Rod end bracket M8, length 18 mm M10, length 21 mm Apply a spanner at the rod end bracket to prevent the rod from receiving any rotating moment when the load is installed. Applying excessive rotating moment to the rod may damage the rod.
3. 3.
Connection diagram [1] When the control board is of the NPN specification [sink type] ERC actuator EMG signal CN1 *Light blue (Red 1) 60 mA max MC *Light blue (Black 1) Yellow (Red 1) Yellow (Black 1) Pink (Red 1) Pink (Black 1) Input power supply (2 A or more) White (Red 1) 24V White (Black 1) 0V FG Brake release switch 2A EMS1 2B EMS2 4A MPI 4B GND 5A MPI 5B GND 3A 24V 3B BKR Motor drive power supply Control power supply OFF when the brake is controlled by the controller,
[2] When the control board is of the PNP specification [source type] ERC actuator EMG signal CN1 *Light blue (Red 1) 60 mA max *Light blue (Black 1) MC Yellow (Red 1) Yellow (Black 1) Pink (Red 1) Pink (Black 1) Input power supply (2 A or more) White (Red 1) 24V White (Black 1) 0V FG 2A EMS1 2B EMS2 4A MPI 4B GND 5A MPI 5B GND 3A 24V 3B BKR Motor drive power supply Control power supply Brake release (Note) switch OFF when the brake is controlled by the controller, or ON when t
3.2 I/O Connections for PIO Pattern 1 [3 Points] (Air Cylinder) The following description assumes that the ERC is used in the place of an air cylinder. The number of positioning points is limited to three, but a direct command input and a position complete output are provided separately for the target position in line with the conventional practice of air cylinder control. Note: The factory setting is “8 points,” so set parameter No. 25 to “1.” The pause signal can be disabled in parameter No. 15.
3.2.2 Details of Input Signals The input signals from this controller have an input time constant, in order to prevent malfunction caused by chattering, noise, etc. Each input signal will switch the applicable setting when received continuously for 6 msec or more. In other words, when a given input is switched from OFF to ON, the controller will recognize the ON state of the signal only after elapse of 6 msec. The same applies to the switching of an input from ON to OFF. (Fig.
3.2.3 Details of Output Signals Completion of each position (PE0 to PE2) These signals indicate that the target position corresponding to each movement command (ST0, ST1 or ST2) has been reached, in the same way the reed switch signal does for an air cylinder. Output signal Meaning of the signal Rear end complete (PE0) The actuator has reached and stopped at the rear end (target position set in position No. 0).
3.3 Note I/O Connections for PIO Pattern 0 [8 Points] The factory setting is “8 points.” The pause signal can be disabled in parameter No. 15.
3.4.1 Explanation of I/O Signals The following explains the signals used in the “8 points” and “16 points” patterns. Category Input Output 3.4.2 Signal name Signal abbreviation Function overview Start CSTR Movement of the actuator starts at the rise edge of this signal. Command position number PC1 PC2 PC4 PC8 This signal is used to input a position number that specifies movement. Be sure to set a command position number by 6 ms before the start signal (CSTR) is turned ON.
Before executing a command using the start signal, make sure the target position, speed and other operation data are set in the position table using a PC or teaching pendant. If a start command is issued when the first home return is not yet completed after the power was input, home return will be performed automatically to establish the coordinates, after which the actuator will move to the target position.
Home return completion (HEND) This signal is OFF immediately after the power is input, and turns ON in either of the following two conditions: [1] Home return operation has completed with respect to the first movement command issued with the start signal. [2] Home return operation has completed following an input of the home return signal. Once turned ON, this signal will not turn OFF until the input power is cut off or the home return signal is input again.
3.5 Configuration Using a SIO Converter If any of the following conditions applies, use a SIO converter to connect the teaching pendant, PC or PLC’s communication module: [1] The actuator’s rear cover cannot be reached and therefore the teaching pendant or PC cannot be connected. [2] Want to execute movement operation or parameter edit for all axes when multiple axes are connected to the single equipment. [3] Want to operate the actuator via serial communication using the PLC’s communication module.
Connection diagram [1] When the control board is of the NPN specification [sink type] SIO converter (RCB-TU-SIO-A/B) EMG signal TB2 Relay 60 mA MAX EMG2 MC Contact output for EMG switch on teaching pendant EMG1 24V ERC actuator 0V FG CN1 TB1 Orange (Red 1) A Orange (Black 1) B MC Yellow (Red 1) Yellow (Black 1) Pink (Red 1) Pink (Black 1) Input power supply White (Red 1) 24V White (Black 1) 0V Brake release switch FG Host system Orange (Red 2) *Light blue (Red 2) Output sid
[2] When the control board is of the PNP specification [source type] SIO converter (RCB-TU-SIO-A/B) EMG signal TB2 Relay 60 mA MAX EMG2 MC Contact output for EMG switch on teaching pendant EMG1 24V ERC actuator 0V FG CN1 TB1 Orange (Red 1) A Orange (Black 1) B MC Yellow (Red 1) Yellow (Black 1) Pink (Red 1) Pink (Black 1) Input power supply White (Red 1) 24V White (Black 1) 0V Brake release (Note) switch FG Orange (Red 2) Host system Output side Orange (Black 2) *Light blue (Red 2
3.6 Configuration Using an Insulated PIO Terminal Block If either of the following conditions applies, use an insulated PIO terminal block: [1] Want to insulate the control power supply from the PIO power supply.
Connection diagram [1] When the control board is of the NPN specification [sink type] Insulated PIO terminal block (RCB-TU-PIO-A/B) TB2 A EMG signal (Not used) B TB1 Relay MC EMS2 60 mA Max EMS1 BK Brake release (Note) switch Input power supply Contact output for EMG switch on teaching pendant 24V 0V MP Motor drive power supply 24V Control power supply Connect to FG 0V J1 FG TB4 FG Relay cable TB3 Host system Input common 1 2 Output side 3 4 5 6 7 I/O interface (Refer t
[2] When the control board is of the PNP specification [source type] Insulated PIO terminal block (RCB-TU-PIO-AP/BP) TB2 A (Not used) B EMG signal TB1 Relay MC EMS2 60 mA Max EMS1 BK Brake release (Note) switch Input power supply Contact output for EMG switch on teaching pendant 24V 0V MP Motor drive power supply 24V Control power supply Connect to FG 0V J1 FG TB4 FG Relay cable TB3 Host system Input common 1 2 Output side 3 4 5 6 7 I/O interface (Refer to 4.
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3.
Connection diagram [1] When the control board is of the NPN specification [sink type] SIO converter (RCB-TU-SIO-A/B) EMG signal TB2 Relay 60 mA Max EMG2 MC Contact output for EMG switch on teaching pendant EMG1 TB1 24V 0V A FG B Twisted pair Insulated PIO terminal block (RCB-TU-PIO-A/B) TB2 A B TB1 EMS2 (Not used) MC Input power supply EMS1 BK Brake release (Note) switch 24V MP Motor drive power supply 24V Control power supply Connect to FG 0V 0V J1 FG TB4 FG Relay cable TB3 H
[2] When the control board is of the PNP specification [source type] SIO converter (RCB-TU-SIO-A/B) EMG signal TB2 Relay 60 mA Max EMG2 Contact output for EMG switch on teaching pendant EMG1 MC TB1 24V 0V A FG B Twisted pair Insulated PIO terminal block (RCB-TU-PIO-AP/BP) TB2 A B TB1 EMS2 (Not used) EMS1 MC Input power supply BK Brake release (Note) switch 24V 0V MP Motor drive power supply 24V Control power supply Connect to FG 0V J1 FG TB4 FG Relay cable TB3 Host system I
3.8 Controlling Multiple Axes via Serial Communication The following operations become possible if multiple axes are controlled: [1] Executing movement operations or parameter edit to all axes by connecting teaching pendant or PC via SIO converter. [2] Performing operations via serial communication with the PLC’s communication module as a host by way of a SIO converter. 3.8.
3.8.3 Wiring Examples for Linking Multiple Axes Using only a SIO converter (The same wiring applies to a configuration for automatic operation via serial communication.
Using both SIO converter and insulated PIO terminal block (Communication with the PLC is performed via parallel I/O connection.) Teaching pendant PC PLC’s communication module SIO converter TB1 A B Insulated PIO terminal block TB2 J1 Actuator 1 J1 Actuator 2 J1 Actuator 3 A B TB2 A B TB2 One-pair shielded cable A B RTON FG TB2 J1 A Actuator 16 B (Note 1) (Note 2) (Note 3) (Note 4) Only on the last axis set the terminal-resistor connection switch to the [RTON] side.
3.9 Emergency-Stop Circuit Examples of internal circuit and recommended circuit are shown below. For auxiliary relays, use relays with a diode for absorbing coil surge.
Example of multi-axes circuit allowing each axis to be connected/disconnected to the teaching pendant 24V 0V External EMG reset switch External EMG switch Relay MC Actuator 1 MC M1 M2 M3 Teaching pendant EMG switch EMS1 EMS2 M1 Actuator 2 Teaching pendant EMG switch EMS1 EMS2 M2 Actuator 3 Teaching pendant EMG switch EMS1 EMS2 M3 Actuator 1 M1 M2 MP1 GND MP1 GND Actuator 2 MP1 GND MP1 GND Actuator 3 M3 MP1 GND MP1 GND 47
3.10 Relay Cable No connector on the counter-actuator end (When connecting the actuator directly to a host system) CN2 B A Actuator end CN1 CB-ERC-PWBIO * * * (Standard cable) CB-ERC-PWBIO * * *-RB (Robot cable) 10 9 8 AMP D-2100 1987654321 7 6 5 4 3 2 (J.S.T. Mfg.) V0.
Connectors on both ends (When using an insulated PIO terminal block) A B A B Terminal-block end CN2 CB-ERC-PWBIO * * *-H6 (Standard cable) 10 9 Actuator end CN1 CB-ERC-PWBIO * * *-RB-H6 (Robot cable) 8 10 9 8 AMP 0-2100 198 76 54 3 21 7 6 5 4 7 6 5 4 3 3 2 2 1 1 50 (J.S.T. Mfg.) V0.
4. 4.1 Electrical Specifications Controller Specification item Description Number of controlled axes 1 axis/unit Supply voltage 24 VDC 10% Supply current 2 A max. Control method Weak field-magnet vector control (patent pending) Positioning command Position number specification Position number Maximum 16 points Backup memory Position number data and parameters are saved in nonvolatile memory. Serial EEPROM can be rewritten 100,000 times.
4.2 4.2.1 I/O Signal Interface Circuit External Input Specifications Item Number of input points Input voltage Input current Leak current Operating voltage Specification 6 points 24 VDC 10% 4 mA/point 1 mA/point or less ON voltage: 18 V min. (3.5 mA) OFF voltage: 6 V max. (1 mA) [NPN specification] ERC CN1 FUSE 3A Power supply (VP24) External power supply 24 VDC GND Each input 5.
4.2.2 External Output Specifications Item Specification Number of output points 4 points Rated load voltage 24 VDC Maximum current 60 mA/point Residual voltage 2 V or less Shorting/reverse-voltage protection Fusing resistor (27 , 0.1 W) [NPN specification] ERC CN1 3A FUSE Power supply (VP24) GND Fusing resistor 27 0.
4.3 SIO Converter (Optional) Model: RCB-TU-SIO-A (Vertical installation) RCB-TU-SIO-B (Horizontal installation) This unit is required if any of the following conditions applies: [1] The actuator’s rear cover cannot be reached and therefore the teaching pendant or PC cannot be connected. [2] Want to execute movement operation or parameter edit for all axes when multiple axes are connected to the single equipment.
[5] PORT switch A switch for enabling/disabling the teaching pendant. Set the switch to ON when a teaching pendant is used, or OFF when teaching pendant is not used.
4.4 Insulated PIO Terminal Block (Optional) Model: RCB-TU-PIO-A (Combined with a NPN control board: Vertical installation) RCB-TU-PIO-B (Combined with a NPN control board: Horizontal installation) RCB-TU-PIO-AP (Combined with a PNP control board: Vertical installation) RCB-TU-PIO-BP (Combined with a PNP control board: Horizontal installation) This unit is required if either of the following conditions applies: [1] Want to insulate the control power supply from the PIO power supply.
[1] Power/emergency-stop terminal block (TB1) EMS1, EMS2 BK MP 24V 0V Provide a contact output for the emergency-stop switch on the teaching pendant (RCA-T/E). EMS1 and EMS2 are provided to comprise an interlock with a safety circuit provided by the user when a teaching pendant with emergency-stop switch is connected to the connector on the rear cover.
[6] PIO connection terminal block (TB3) A PLC connection port. Detailed signal specifications are shown below.
Internal connection diagram [1] RCB-TU-PIO-A/B Actuator end Host system end Connector Nonpolar input photocoupler Input common 6 circuits 6 circuits Fusing chip resistor 4 circuits 4 circuits Output common 58
[2] PCB-TU-PIO-AP/BP Actuator end Host system end Connector Nonpolar input photocoupler Input common 6 circuits 6 circuits Fusing chip resistor 4 circuits 4 circuits Output common 59
I/O interface specifications Input Specifications Specification item Number of input points Description 6 points Input voltage 24VDC 10% Input current 7 mA/point (bipolar) Allowable leak current Operating voltage 1 mA/point (approx. 2 mA at normal temperature) ON voltage: 16 V min. (4.5 mA) OFF voltage: 5 V max. (1.
5. Data Entry This actuator doesn’t use command words, so there is no need to create a program. All you need is to enter the target position in the position-data table, and the actuator will move to the specified position. Position data consists of number (No.), target position (Position), speed (Speed), acceleration/deceleration (ACC), push (Push), positioning band (Pos. band), and acceleration only MAX (ACC MAX). The description in parentheses is as displayed on the teaching pendant.
5.1 Description of Position-Data Table (1) No. Indicate the position data number. To enter an incremental movement, press the minus key in this column. On the teaching pendant, a “=” will be displayed between the number and position columns. The minus key need not be pressed in the absolute mode. (2) Target position (Position) Enter the target position to move the actuator to, in [mm]. Absolute mode: Enter the distance to the target actuator position from the home.
Select the positioning mode or push & hold mode. The default value is “0.” 0: Positioning mode (= Normal operation) Other than 0: Push & hold mode [%] To select the push & hold mode, enter the current-limiting value for the servo motor during push & hold operation. Enter an appropriate value up to 70% in accordance with the actuator type. (5) Push (Push) Be sure to refer to 5.1.
(7) Acceleration only MAX (ACC MAX) Select the specified acceleration or maximum acceleration by entering “0” or “1.” The default value is “0.” 0: Specified acceleration --- The value entered in (4) becomes the actual acceleration/deceleration. 1: Maximum acceleration --- The maximum acceleration is applied only during acceleration. During deceleration, the value input in (4) is used.
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5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value When performing operation in the push & hold mode, enter the current-limiting value (%) in the push column of the position-data table. Determine the current-limiting value (%) from the push force to be applied to the load at standstill.
● Rod type (1) RA54 type (2) RA64 type Low-speed type (Lead: 3 mm) Low-speed type (Lead: 4 mm) 350 250 Push force (N) Push force (N) 300 200 150 100 50 0 20 30 40 50 60 70 900 800 700 600 500 400 300 200 100 0 20 Medium-speed type (Lead: 6 mm) 160 140 120 100 80 60 40 20 0 20 30 40 50 60 70 450 400 350 300 250 200 150 100 50 0 20 Push force (N) Push force (N) 50 40 30 40 50 60 Current-limiting value (%) 30 60 70 40 50 60 70 High-speed type (Lead: 16 mm) 250 80 70 60
5.2 Explanation of Modes Positioning Mode Moving distance 5.2.2 Push = 0 Position complete signal Output Speed 5.2.1 Push & Hold Mode (1) The position complete output will turn ON at a position preceding the target position by the positioning band. Positioning band Push = Other than 0 Speed (1) Load was contacted successfully Position complete signal Output Moving distance Positioning band (1) After reaching the target position, the actuator will move at low speed (75 rpms). When the Pos.
(2) Load was not contacted (missed) Speed Position complete signal is not output Moving distance Positioning band (1) After reaching the target position, the actuator will move at low speed. Even after contacting the load, the actuator will move to the end of the positioning band if the stepper motor current is yet to reach the currentlimiting value. The position complete output will not turn ON even when the end of the positioning band is reached.
Positioning band was entered with a wrong sign Speed (4) If the positioning band is entered with a wrong sign, the position will deviate by twice the positioning band, as shown to the left, so exercise due caution. Moving distance 5.2.3 Positioning Positioning band band Speed Change during Movement Speed control involving multiple speed levels is possible in a single operation. The actuator speed can be decreased or increased at a certain point during movement.
5.2.5 Pause The actuator can be paused during movement using an external input signal (*pause). The pause signal uses the contact B logic (always ON) to ensure safety. Turning OFF the *pause input will cause the actuator to decelerate to a stop, while turning it ON will allow the actuator to complete the remaining operation.
6. 6.1 Operation in the “3 Points (Air Cylinder)” Mode Overview of the “3 Points” Mode This mode provides a control method adjusted to that of an air cylinder by assuming that the ERC is used as an air cylinder. The key differences between the ERC and an air cylinder are summarized below. Perform proper control by referring to this table.
The relationships of movement command inputs/position complete outputs and corresponding position numbers are shown below. For easier identification, each input/output signal has a name similar to the naming convention used with air cylinders. However, note that the target position is determined by the value set in the [Target position] field under each position number. Therefore, changing the magnitude correlation of the settings in Nos.
6.2 (1) (2) (3) (4) (5) How to Start Confirm that the connector end (CN1) of the relay cable is firmly plugged into the connector on the actuator cable. Connect the PLC and the parallel I/O. If the actuator has brake, set the brake release switch to OFF. Supply 24 VDC to the control power supply. Cut off the motor-drive power supply (actuate an emergency stop) beforehand. Confirm that the slider or rod is not contacting the mechanical end.
If the actuator does not perform home return, confirm that the *pause signal is ON, the motor-drive power supply is receiving power, and no error messages are displayed, among others. (10) Set the target position, speed, acceleration/deceleration, positioning band and other data in the position table. For details on how to set data in the position table, refer to the operation manual for the teaching pendant or PC software, whichever is applicable.
6.3 Moving Operation First, make the controller ready to accept movement commands by referring to 6.2, “How to Start.” Example of use in operation) Turn on the power, and then cause the actuator to move back and forth between the rear end (5 mm) and front end (390 mm) via an intermediate point (200 mm).
[Operation timings] Rear end move Intermediate point move Front end move Rear end complete Intermediate point complete Front end complete Speed Actuator movement Mechanical Home end position Rear end Intermediate point Front end Note: Movement commands are executed based on the rise edge, so input each signal continuously for 6 msec or more.
The movement command input operates in two modes. You can select the operation condition of the movement command input (ST0 to ST2) in parameter No. 27. The factory setting is “0: [Level mode].” Description of the movement command input Level mode: The actuator starts moving when the input signal turns ON. When the signal turns OFF during the movement, the actuator will decelerate to a stop and complete its operation.
Handling of the pause (*STP) signal This signal is a Contact B signal, meaning that it must remain ON while the actuator is moving. If the pause signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. The actuator will start moving when the signal turns ON again. Use this signal as an interlock that actuates when an operator entry prohibition sensor or contact prevention sensor is activated. If the pause signal is not to be used, set parameter No.
7. 7.1 (1) (2) (3) (4) (5) Operation in the “8 Points” and “16 Points” Modes How to Start Confirm that the connector end (CN1) of the relay cable is firmly plugged into the connector on the actuator cable. Connect the PLC and the parallel I/O. If the actuator has a brake, set the brake release switch to OFF. Supply 24 VDC to the control power supply. Cut off the motor-drive power supply (actuate an emergency stop) beforehand.
If the actuator does not perform home return, confirm that the *pause signal is ON, the motor-drive power supply is receiving power, and no error messages are displayed, among others. (10) Set the target position, speed, acceleration/deceleration, positioning band and other data in the position table. For details on how to set data in the position table, refer to the operation manual for the teaching pendant or PC software, whichever is applicable.
7.2 How to Execute Home Return First, force the position complete signal to turn ON by referring to 7.1, “How to Start.” 7.2.1 8 Points Enter the home return signal (HOME). When home return is completed, the home return completion signal (HEND) and position complete signal (PEND) will be turned ON. Home return HOME Position complete PEND Home return completion HEND Actuator movement Mechanical end Stops at the home position.
7.2.2 16 Points Input a start signal after selecting and inputting a desired command position number in which a target position is registered. Home return is executed first, and then the actuator will move to the target position. The home return completion signal (HEND) will be turned ON at the home position, and upon reaching the target position the position complete signal (PEND) will be turned ON. To stop the actuator at the home position, set the target position to “0.
7.3 Home Return and Movement after Start (16 Points) First, set the necessary data in the position table by referring to 7.1, “How to Start. If home return has not yet been executed immediately after the system start, issuing a start command by specifying a position will cause the actuator to return to the home before moving to the specified position.
Position 1 Command position T1 Start Note Position complete Home return completion Positioning band Speed Actuator movement Time Mechanical end Home The position complete output will turn ON when the controller becomes ready following the power ON. To check if the controller is ready, always check if the position complete output is ON. The actuator will not operate unless the pause input is turned ON.
7.4 Positioning Mode (Back and Forth Movement between Two Points) Example of use in operation) The actuator moves back and forth between two positions. The position 250 mm from the home is set as position 1, and the position 100 mm from the home is set as position 2. The travel speed to position 1 is set as 200 mm/sec, and to position 2 is set as 100 mm/sec.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * Push Positioning band * * Acceleration only MAX * 1 250 200 2 100 100 0.3 0 0.1 0 0.3 0 0.
7.5 Push & Hold Mode First, cause the position complete signal to turn ON by referring to 7.1, “How to Start.” Example of use in operation) The actuator is caused to move back and forth in the push & hold mode and positioning mode. The position 280 mm from the home is set as position 1, and the position 40 mm from the home is set as position 2. Movement to position 1 is performed in the push & hold mode (the actuator is caused to contact the load and push it in the counter-motor direction).
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * Push Positioning band * * Acceleration only MAX * 1 280 200 0.3 50 15 0 2 40 100 0.3 0 0.
7.6 Speed Change during Movement Example of use in operation) The actuator speed is reduced at a certain point during movement. The position 150 mm from the home is set as position 1, and the position 200 mm from the home is set as position 2. The actuator is initially located between the home and position 1. The actuator is moved to position 2 being the target position, at a travel speed of 200 mm/sec to position 1 and that of 100 mm/sec from position 1 to position 2.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * 1 150 200 0.3 2 200 100 0.3 Push Positioning band * * Acceleration only MAX * 0 10 0 0 0.
7.7 Operation at Different Acceleration and Deceleration Settings Example of use in operation) Positioning is performed to the position 150 mm from the home (position 1) at a speed of 200 mm/sec. The actuator will accelerate at the maximum acceleration set according to the load, and decelerate at 0.1 G. Method) Entering “1” under “Acceleration only MAX” in the position data will automatically adjust the acceleration to the maximum acceleration set according to the load. Entering “0.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * 1 150 200 0.1 Push Positioning band * * Acceleration only MAX * 0 0.1 1 Command position Position 1 T1 Start Position complete Speed Positioning band Actuator movement Acceleration at maximum motor torque T1: 0.
7.8 Pause Example of use in operation) The actuator is paused during movement. Method) Use the pause input. ERC controller Reference flow PIO Signal name [4] [2] P Category Select/enter a desired command position. [2] Start input ON Start Command position 1 [1] [1] Command position 2 Input Movement to the selected position starts.
Command position T1 Start Note Position complete Pause Speed Actuator movement Deceleration to a stop T1: Start of remaining movement 6 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Note: When the start signal turns ON, the position complete output will turn OFF.
7.9 Zone Signal Output Example of use in operation) While the actuator is moving a zone signal is output inside the zone enclosed by distances of 40 mm and 120 mm from the home. (40 mm Zone signal output 120 mm) Method) Use the parameters “Zone boundary+” and “Zone boundary–” to set the zone in which the zone signal is output, as shown below: Parameter No. 1 Zone boundary+ 120 Parameter No.
Command position T1 Start Note Position complete Zone Speed Actuator movement 40 mm T1: 120 mm 6 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Note: When the start signal turns ON, the position complete output will turn OFF. The start signal must be turned OFF with the confirmation that the position complete output has turned OFF while the start signal remains ON.
7.10 Incremental Moves Example of use in operation) The actuator is caused to move from the home to the 30-mm position, from which it will be moved repeatedly in increments of 10 mm. The travel speed from the home to the 30-mm position is set as 100 mm/sec, and that for 10-mm incremental moves is set as 20 mm/sec. ERC controller Reference flow PIO Signal name [9] [7] [4] [2] P [1] [6] Category [2] Start input ON Start Command position 1 Command position 2 Movement to position 1 starts.
Position-data table (Field(s) within thick line must be entered.) 0 * * Acceleration/ deceleration * 1 2 30 10 100 20 0.3 0.3 No. Position = Speed * * Acceleration only MAX * 0 0 0.1 0.
7.11 Notes on Incremental Mode (1) Notes on positioning operation Selecting/entering a position number using relative coordinates during positioning will cause the actuator to move to the position corresponding to the initial position plus the increment. (If the increment is a negative value, the actuator will move to the position corresponding to the initial position minus the increment.
Example) If the start signal for movement to position 2 is input while the actuator is moving to position 1 in the push & hold mode, the actuator will move to the position 10 mm from where it was when the input signal was input. No.
8. Parameters 8.1 Parameter Classification Parameters are classified into four types according to their content. Category: a: Parameter relating to the actuator stroke range b: Parameter relating to the actuator operating characteristics c: Parameter relating to the external interface d: Servo gain adjustment 8.2 Parameter Table No.
8.3 Parameter Settings If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power. 8.3.1 Parameters Relating to the Actuator Stroke Range Soft limit Set the soft limit in the positive direction in parameter No. 3, and that in the negative direction in parameter No. 4. The factory setting for the soft limits conforms to the effective actuator length.
Home return direction Unless specified by the user, the home return direction is set to the motor direction at the factory. Should a need arise to change the home direction after the actuator has been assembled into your system, reverse the setting in parameter No. 5 between “0” and “1.” Also change the home return offset, if necessary. If necessary, also change the parameters for home return offset, soft limits and excited-phase signal detection direction.
Default acceleration only MAX flag To cause the actuator to decelerate gradually when stopping, a lower acceleration/deceleration should be set. However, this will also reduce the acceleration. This parameter allows for quick acceleration while reducing the deceleration. However, the actual load must be one-third the rating or less. Check the payload rating by referring to 1.3, “Specifications.” The factory setting is “0: [Disable].
Current-limiting value during home return The factory setting conforms to the standard specification of the actuator. Increasing this setting will increase the home return torque. This setting need not be changed in normal conditions of use. However, if an increased slide resistance causes the home return to complete before the correct position depending on the affixing method, load condition or other factor when the actuator is used in a vertical application, the value set in parameter No.
8.3.3 Parameters Relating to the External Interface PIO pattern selection Select a desired PIO operation pattern using parameter No. 25. This parameter sets the basis of operation, so be sure to set it first. The factory setting is “0: [8 points].” Setting of parameter No. 25 0 1 2 Feature of the PIO pattern 8 points The basic pattern providing eight positioning points. 3 points (air cylinder) Use of the ERC as an air cylinder is assumed in this pattern.
[Level mode] Movement command input (ST0 to ST2) Position complete (PE0 to PE2) Stopped Actuator movement Target position (Note) Turn OFF the movement command input after confirming that the target position has been reached. [Edge mode] Movement command input (ST0 to ST2) Position complete (PE0 to PE2) Actuator movement Target position Pause input disable selection Parameter No. 15 defines whether the pause input signal is disabled or enabled.
8.3.4 Servo Gain Adjustment Servo gain number The factory setting is optimized in accordance with the standard specification of the actuator. This setting need not be changed in normal conditions of use. However, an increased load may produce noise during downward movements depending on the affixing method, load condition or other factor when the actuator is used in a vertical application. In this case, decreasing the value set in parameter No. 7 will be effective.
9. Troubleshooting 9.1 Action to Be Taken upon Occurrence of Problem Upon occurrence of a problem, take appropriate action according to the procedure below in order to ensure speedy recovery and prevent recurrence of the problem. a) Check the status indicator lamps. Illuminating in green --- The servo is ON. Illuminating in red --- An alarm is present or the motor drive power is cut off. b) Check for error in the host controller. c) Check the voltage of the main 24-VDC power supply. d) Check for alarm.
9.3 Alarm Description and Cause/Action (1) Message level alarms Code Error name Cause/Action 41 Motor voltage drop This alarm indicates that the motor drive power is cut off. (This is not an error.) 5A Reception overrun 5B Reception framing error 5D Header error 5E Delimiter error 7F BCC error This alarm indicates an error during PC or teaching pendant operation or in the serial communication using the PLC’s communication module.
(2) Operation-cancellation level alarms Code B0 Error name Bank 30 data error Cause/Action Cause: Action: B1 Bank 31 data error Cause: Action: BE Home return timeout Cause: Action: C0 Excessive actual speed Cause: Action: Data in the parameter area is outside the input range or invalid. (This alarm will not generate in normal parameter input operation, but may occur during serial communication using the PLC’s communication module.
Code Error name CA Overheating CC Abnormal control supply voltage CE Drop in control supply voltage Cause/Action This alarm indicates that the temperature around the power transistor in the controller board is too high (95C or higher). Cause: [1] High temperature around the actuator [2] Faulty part inside the controller board Action: Reduce the temperature around the actuator. If the temperature around the actuator is normal, please contact IAI.
9.4 Messages Displayed during Operation Using the Teaching Pendant or PC Software This section explains the warning messages that may be displayed during operation using the teaching pendant or PC software. Code Error name 112 Invalid data 113 114 Value too small Value too large 115 Cause/Action An inappropriate value was entered in a user parameter. (Example) 9601 was entered as the serial communication speed by mistake. Enter an appropriate value again.
Code Error name Cause/Action 20C CSTR-ON during operation This message indicates that the start signal (CSTR) was turned ON by the PLC while the actuator was moving, and that duplicate movement commands occurred as a result. 20D STP-OFF during operation This message indicates that the pause signal (*STP) was turned OFF by the PLC while the actuator was moving, and that the movement was disabled as a result. 20E Soft limit over This message indicates that a soft limit was reached.
9.5 Specific Problems I/O signals cannot be exchanged with the PLC. Cause: [1] The 24-V power supply is connected in reverse. (This will not affect the input circuits, but the output circuits may be damaged.) [2] If the problem is with an output circuit, the fusing resistor may have blown due to a large load that caused the current flowing into the circuit to exceed the maximum current. [3] Contact failure in the connector or relay terminal block on the PLC end.
Vibration occurs when the actuator is stopped. Cause: The slider is receiving an external force. Action: If the external force cannot be removed, increase the value set in user parameter No. 12 (Currentlimiting value at standstill during positioning). Increasing this value will cause the holding torque at standstill to increase, so do not increase the parameter setting above 70%. The actuator overshoots when decelerated to a stop.
10. Maintenance and Inspection 10.1 Inspection Items and Timings Perform maintenance and inspection per the schedule specified below. This schedule assumes eight hours of operation a day. Shorten the inspection intervals if the utilization is higher, such as when the actuator is operated continuously day and night.
10.4 Internal Check (Slider Type) [1] With the SA6 and SA7, the screw cover and side covers can be removed using a hex wrench with 1.5 mm width across flats. The front and rear brackets are supporting the ball screw, so do not disassemble these brackets. Precision instrument is assembled into the motor cover, so do not disassemble the motor cover. [2] Visually check the internal condition. Check for intrusion of dust and other foreign object, and also check the lubrication condition.
10.5 Internal Cleaning (Slider Type) Wipe off dirt using a soft cloth, etc. Do not blow compressed air at high speed. Doing so may cause dust to enter the actuator through gaps. Do not use petroleum solvent, neutral detergent or alcohol. Note: Do not use cleaning oil, molybdenum grease or rustproof lubricant. If a large amount of foreign object is contained in the grease, wipe off the dirty grease before applying new grease. 10.
(2) Greasing method Grease the guide by following the procedure below: [1] Apply grease between the slider and base, as shown to the left. Apply grease on the opposite side in the same manner. [2] Spread the grease evenly between the slider and base using a spatula, as shown to the left. Spread the grease evenly on the opposite side in the same manner. [3] Move the slider back and forth several times by hand. [4] Repeat steps [1], [2] and [3]. [5] Use a waste cloth, etc.
10.7 Greasing the Ball Screw (Slider Type) (1) Applicable grease The following special grease is applied to the ball screw prior to shipment: Kyodo Yushi Multemp LRL3 This grease generates less heat and has other excellent properties suitable for ball screws. For equivalent grease products, refer to the brands specified for the guide (lithium grease). Note to the user: Never use fluorine grease.
10.8 Greasing the Rod Slide Surface (1) Applicable grease The following grease is applied to the rod slide surface prior to shipment: Kyodo Yushi Multemp LRL3 Use lithium grease for maintenance. Note to the user: Never use fluorine grease. If fluorine grease is mixed with lithium grease, the grease function will drop and it causes damage to the mechanism.
10.9 Motor Replacement Procedure Before replacing the motor, save the latest parameter and position data. Save the data by one of the following methods: Save the data to a file using the PC software. Prepare position/parameter tables and manually write the values. When a new motor has been installed, enter the parameter/position data to the controller.
Installation [1] Place the coupling spacer in the coupling hub. [2] Insert the motor unit into the rear bracket while paying attention to the phase of the coupling hub with respect to the coupling spacer. (When inserting the motor unit, exercise due caution to prevent pinching of parts.) [3] Insert the coupling bolt into the fitting hole in the motor unit from over the rear bracket, and tighten the bolt using a wrench with 3 mm width across flats.
Appendix * Appendix Example of Basic ERC Positioning Sequence Given below is an example of basic sequence for creating a positioning sequence using the ERC. indicates PIO signals of the ERC controller.
Appendix (Positioning circuit for position 2) Positioning start request to position 2 N M M Positioning start pulse to position 2 Ｎ Auxiliary positioning start pulse to position 2 O Auxiliary positioning start for position 2 P Start check for position 2 Q Completion of positioning to position 2 R Position 1 set S Position 2 set Positioning start request to position 2 N M P O O PEND Q P P PEND Auxiliary start signal for next positioning If a measure is taken to identify the curre
Appendix R PC1 Command position 1 PC2 Command position 2 PC4 Command position 4 Position 3 set signal Position 5 set signal S Position 3 set signal Position 6 set signal (Start signal circuit) J O Start command for positioning to other position Timer 2 Waiting for start 5 msec or more (Must be longer than the PLC’s scan time.
Appendix Recording of Position-Data Table Recorded date: No.
Appendix Parameter Records Recorded date: Category a: b: c: d: Parameter relating to the actuator stroke range Parameter relating to the actuator operating characteristics Parameter relating to the external interface Servo gain adjustment No.
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Appendix Change History Revision Date January 2011 Description of Revision Seventh edition Added “Before Use.” Changed “Safety Precautions” to “Safety Guide.” P. 6: Added 1.3.3, “Sound Pressure Levels of This Product Will Not Exceed 70 dB.” P. 14: Moved “Prohibited Handling of Cables” to after 1.8, “Cabling.
Catalog No.: ME0137-7A 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 Kennestone Circle, Suite 108, 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 IAI (Shanghai) Co., Ltd.
