ERC2 Actuator with Integrated Controller (PIO Type) Operation Manual Fifth 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 or DVD that comes with the product contains operation manuals for IAI products.
CAUTION 1. Using Multiple 24-V Power Supplies If multiple 24-V power supplies are used, always connect the 0-V lines of all power supplies. If not, damage to the controller board, SIO converter or other components may occur.
CAUTION 2. Basic Parameter Settings When the power is turned on for the first time, at least the two parameters explained below must be set in accordance with your specific application. Remember to always set these parameters properly, because improper settings will prevent the product from operating correctly. For details on how to set these parameters, refer to “parameter settings” of the PC software or teaching pendant.
CAUTION 3. PC Software and Teaching Pendant Models This product offers new functions not available in the conventional ERC series. To support these new functions, the communication protocol has been changed to a general Modbus-compliant protocol. Accordingly, the PC software programs and teaching pendants that have been used with the ERC series are no longer compatible with the ERC2 series. Select a compatible program or teaching pendant from among the model numbers listed below.
CAUTION 5. Plugging/Unplugging ERC2PIO Teaching Tools [1] When plugging or unplugging a teaching tool (PC software/teaching pendant) connector, make sure the power is turned off. If the connector is plugged or unplugged while the power is on, internal circuits may be damaged. Teaching pendant (optional) PC software (optional) Do not plug or unplug these connectors when the ERC2 power is on.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Safety Guide........................................................................................................................................ 1 1. Overview ...................................................................................................................................... 1 9 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2. Installation .................................................................................................................................. 15 24 2.
3.7 3.8 3.9 3.10 3.11 4. Electrical Specifications.............................................................................................................. 69 4.1 4.2 4.3 5. Movement to each position (ST0 to ST2).............................................................................. 51 Pause (*STP) ........................................................................................................................ 51 Alarm reset (RES) ...................................................
5.3 6. Operation in the “3 Points (Air Cylinder)” Mode ...................................... 93 6.1 6.2 6.3 6.4 7. Overview of the “3 Points” Mode............................................................................................................... 93 How to Start .............................................................................................................................................. 95 Position Table and Parameter Settings Required for Operation....
8.2.3 8.2.4 9. Default direction of excited-phase signal detection ............................................................. 134 Excited-phase signal detection time.................................................................................... 134 Safety speed ....................................................................................................................... 134 Automatic servo-off delay time ....................................................................................
11.1.3 11.1.4 11.1.5 11.1.6 11.1.7 11.1.8 11.2 11.3 11.4 ERC2-RA6C ............................................................................................................................. 163 ERC2-RA7C ............................................................................................................................. 164 ERC2-RGS6C .......................................................................................................................... 165 ERC2-RGS7C .........................
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health Work area Work condition Outside During automatic movement range operation Cutoff of drive source Not cut off Measure Signs for starting operation Installation of railings, enclosures, etc. Cut off Sign, etc., indicating that work is in (including stopping of progress operation) Preparation of work rules Measures to enable immediate stopping During teaching, of operation etc. Sign, etc.
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health Safety Guide Work area Work condition Cutoff of drive source Measure Article “Safety Guide”During has been written to use the machine Signs safelyfor and so prevent personal injury or property Outside automatic starting operation Article 104 Not cut off movement range operationMake sure to read it before theInstallation damage beforehand. operationofofrailings, this product. enclosures, etc. Article 150-4 Cut off Sign, etc.
Safety Guide Operation This “Safety and prevent dangers and property damage. No. Guide” is intended to ensure the correct use of this product Description Description Be sure to read this section before using your product. 2 Transportation Ɣ When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane.
Applicable Modes of IAI’s Industrial Robot Operation No. Description Description Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor 4 No. 51 and Notice of Ministry of Labor/Labor Installation (2) Cable Wiring Standards Office Director (Ki-Hatsu No.
Notes on Safety of Our Products Operation Common robot are explained below. No. items you should note when performing each task on any IAI Description Description No. 4 Task Note Installation (4) Safety Measures not work planned or designed for uses high degrees Start z This Ɣproduct Whenisthe is carried out with 2 orrequiring more persons, makeofitsafety.
No. Task Note (2) Wiring the cables 4 Installation/ z Use IAI’s genuine cables to connect the actuator and controller or connect a teaching tool, startup Operation No. Description Description etc. z Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place 6 Trial Operation Ɣ articles When the work is carried out with 2 or more persons, clear who is heavy on top.
No. Task 5 Teaching 6 7 8 9 10 Note z When releasing the brake of the vertically installed actuator, be careful not to let the Operation actuator drop due to its dead weight, causing pinched hands or damaged work part, etc. No. Description * Safety fences --- Indicate the movement range if safety fences are not provided.
Indication of Cautionary Information Alert Indication The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and “Note,” as specified below.precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the The safety warning level, as follows, and described in the Instruction Manual for each model.
Caution in Handling 1. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings. If the actuator is operated at a speed or acceleration/deceleration exceeding the allowable value, abnormal noise or vibration, failure, or shorter life may result. In the case of interpolated operation of combined axes, the speed and acceleration/deceleration settings should correspond to the minimum values among all combined axes. 2. Keep the load moment within the allowable value.
1. Introduction Thank you for purchasing the Easy All-in-One ROBO Cylinder (hereinafter referred to as “ERC2”). This manual explains the features and operating procedures of the product. This product retains all benefits of the conventional ERC series, while incorporating new features that provide greater convenience and enhanced safety to the users. Please read this manual carefully and handle the product with utmost care while ensuring its correct operation.
1. Overview 1.2 Meaning of the Model Number (5& 6$ & , 30 13 6 10 Slider type x SA6C x SA7C Rod type x RA6C x RA7C x RGS6C x RGS7C x RGD6C x RGD7C Blank: No option B: With brake NM: Reversed-home specification FT: Foot bracket (Specified only for rod types.
1.3 Specifications Payload capacity (Note 2) Horizontal Vertical Rated acceleration Horizontal Vertical Rod type Slider type Stroke (mm) and maximum speed (mm/sec) (Note 1) 1. Overview 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 payload capacity is based on operation at the rated acceleration.
Correlation Diagrams of Speed and Payload Capacity – Slider Type 1. Overview 1.3.1 Vertical installation Payload capacity (kg) Payload capacity (kg) High-speed type Horizontal installation Speed (mm/sec) Payload capacity (kg) Payload capacity (kg) Medium-speed type Speed (mm/sec) Speed (mm/sec) (Note) 12 4 Speed (mm/sec) Payload capacity (kg) Payload capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) In the above graphs, the number after each type name indicates the lead.
1.3.2 Correlation Diagrams of Speed and Payload Capacity – Rod Type Payload capacity (kg) Payload capacity (kg) High-speed type Vertical installation Speed (mm/sec) Payload capacity (kg) Payload capacity (kg) Medium-speed type Speed (mm/sec) Speed (mm/sec) Payload capacity (kg) Payload capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) (Note) 1. Overview Horizontal installation Speed (mm/sec) In the above graphs, the number after each type name indicates the lead.
1. Overview 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 overhang length and payload capacity. If the slider is used in an overhang 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 Period and Scope of Warranty 1.4 Warranty Warranty 1 Warranty Period One of the following 1. Warranty Period periods, whichever is shorter: y 18 months after shipment from our company The warranty period shall be of the following periods, whichever ends first: y 12 months after delivery to one the specified location x x 18 months after shipment from our factory 12 months after delivery to a specified location 2 Scope of Warranty 2.
1.4 Warranty and Scope of Warranty 5 Conditions of Period Conformance with Applicable Standards/Regulations, Etc., and 1. Overview Applications The ERC2 you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The unit is covered the following warranty: (1) If our by product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules.
1.5 1.5.1 Transportation and Handling Handling before Unpacking x x x x 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. 1.5.2 Handling after Unpacking Once removed out of the box, hold the actuator by the frame if it is a rod type, or by the base if it is a slider type.
1. Overview 1.6 Installation Environment and Noise Elimination Pay due attention to the installation environment of the controller. 1.6.1 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 40qC. [4] Humidity of 85% or less without condensation.
1.6.3 Power Supply The control/motor-drive power supply specification is 24 VDC r 10% (2 A max). 1. Overview 1.6.4 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 mm 2 or larger. [2] 10 Actuator with integrated controller Other equipment Class D grounding Good Actuator with integrated controller Other equipment Avoid this grounding method.
1. Overview (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 m [2] Point Install a surge absorber to each coil over a minimum wiring length.
1.7 x x The standard extension cables have excellent flexibility to withstand fatigue from flexural loads, but they are not robot cables. Therefore, avoid storing the standard extension cables in movable cable ducts laid at a small radius. If they must be stored in movable cable ducts, use robot cables.
1. Overview Prohibitions/Notes on Handling 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. 4.
7. Notes on use of cable tracks z The supplied cables are not robot cables, so do not store them in cable tracks. 1. Overview z Always use a robot cable for each relay cable. Bending radius (r) z Use a cable track with a bending radius (r) of 50 mm or more. z Do not let the cable get tangled or kinked in a cable track 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 Slider Type (SA6C/SA7C) 2. Installation 2.1.1 Coupling bolt Screw cover Right Non-motor end Motor end Side cover Left Top Front bracket Rear bracket LED Motor bracket Rear cover Slider 2.1.2 Motor cover Base Bottom Cable Connection port for teaching pendant or PC (The arrow on the connector should face down.
2.1.3 (1) Rod Type with a Single Guide (RGS6C/RGS7C) Coupling bolt LED Right 2. Installation 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.
2.2 2.2.1 Installation Slider Type 2. Installation z 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: z Affixing with a flange Caution: 2. Installation Install the actuator by tightening from the motor end side with hex cap bolts using the holes provided in the flange. 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 RA6C M5 3.4 Nm (0.35 kgfm) RA7C M6 5.
z Affixing with foot brackets (optional) 2. Installation If optional foot brackets are used, install the foot brackets using hex cap bolts. Foot-bracket tightening bolts Model RA6C RGS6C RGD6C RA7C RGS7C RGD7C 28 Nominal thread size Tightening torque M6 5.4 Nm (0.55 kgfxm) M8 11.5 Nm (1.
2.2.3 Installing the Load z Slider Type 2. Installation 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). Nominal thread size M5 Type Slider mounting hole SA6C, SA7C 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.
z Rod Type 2. Installation 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 Note) Model Rod end bracket RA6C M8, length 18 mm RA7C M10, length 21 mm Apply a spanner wrench 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. 3.1 Wiring Basic Structure 3.
z Connection diagram [1] When the control board is of the NPN specification [sink type] ERC2 actuator 3.
[2] When the control board is of the PNP specification [source type] ERC2 actuator CN1 *Light blue (Red 1) Relay MC 60 mA max.*Light blue (Black 1) Yellow (Red 1) Yellow (Black 1) Pink (Red 1) Input power supply (2 A or more) Pink (Black 1) White (Red 1) 24V 0V FG 3.
3.2 Configuration Using a SIO Converter If any of the following conditions applies, use a SIO converter to connect the teaching pendant or PC: [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.
z 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 M Contact output for EMG switch on teaching pendant EMG1 24V 3.
[2] When the control board is of the PNP specification [source type] SIO converter (RCB-TU-SIO-A/B) EMG signal 3.
3.2.1 Example of Connecting Multiple Axes Using Link Cables Teaching pendant PC 3. Wiring SIO converter Relay terminal block Actuator 1 Actuator 2 Actuator 3 One-pair shielded cable Terminal resistor 1/2W, 220 : (Note 1) (Note 2) (Note 3) (Note 4) 28 Actuator 16 If the total length of the communication cable is 10 m or longer and you experience communication errors, connect a terminal resistor to the last axis. If the actuators use different power supplies, align 0 [V] on all power supplies.
3.2.2 Address Assignment 3. Wiring If multiple axes are connected, a slave number must be assigned to each axis so that the host can recognize the corresponding actuator. Assign addresses in the setting screen of the teaching pendant or PC. z Overview of operation on the PC [1] Open the main window o [2] Click Setup (S) o [3] Bring the cursor to Controller Setup (C) o [4] Bring the cursor to Assign Address (N) and click the mouse o [5] Enter an appropriate number in the address table.
3.3 Configuration Using an Isolated PIO Terminal Block If either of the following conditions applies, use an isolated PIO terminal block: [1] Want to insulate the control power supply from the PIO power supply. [2] Want to change the I/O logic of the control board. 3.
z 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 3.
[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) 3.
3.4 Configuration Using Both SIO Converter and Isolated PIO Terminal Block PC software RS232C type Optional 3.
z 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 EMG1 Contact output for EMG switch on teaching pendant 0V A FG B 3.
[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 3.
3.4.1 Example of Connecting Multiple Axes Using Link Cables Teaching pendant PC 3. Wiring SIO converter Insulated PIO terminal block Actuator 1 Actuator 2 One-pair shielded cable Actuator 3 Actuator 16 (Note 1) (Note 2) (Note 3) (Note 4) 36 Only on the last axis set the terminal-resistor connection switch to the [RTON] side. If the actuators use different power supplies, align 0 [V] on all power supplies. Connect the shielded wire of each axis to FG.
3. Wiring 3.4.2 Address Assignment If multiple axes are connected, a slave number must be assigned to each axis so that the host can recognize the corresponding actuator. Assign addresses in the setting screen of the teaching pendant or PC. z Overview of operation on the PC [1] Open the main window o [2] Click Setup (S) o [3] Bring the cursor to Controller Setup (C) o [4] Bring the cursor to Assign Address (N) and click the mouse o [5] Enter an appropriate number in the address table.
3.5 3.5.1 Specifications of I/O Signals Recognition of Input Signals Input signal Not recognized Not recognized Recognition by the controller 6 [msec] 6 [msec] Fig. 1 Recognition of Input Signal 38 47 3. Wiring 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.
3.5.2 External Input Specifications Item 3. Wiring Number of input points Specification 6 points Input voltage 24 VDC r 10% Input current 4 mA/circuit Leak current 1 mA/point or less Operating voltage ON voltage: OFF voltage: 18 V min. (3.5 mA) 6 V max. (1 mA) [NPN specification] ERC2 CN1 FUSE 3A Power supply (VP24) External power supply 24 VDC GND Each input 5.
3.5.3 External Output Specifications Item Specification Number of output points 4 points Rated load voltage 24 VDC 60 mA/point Residual voltage 2 V or less Shorting/reverse-voltage protection [NPN specification] 3. Wiring Maximum current Fusing resistor (27 :, 0.1 W) ERC2 CN1 3A FUSE Power supply (VP24) GND Fusing resistor 27 : 4 output points 0.
3.6 I/O Signals for PIO Pattern 1 [3 Points] (Air Cylinder) The following description assumes that the actuator is used in 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. 3. Wiring Caution: The factory setting is “8 points,” so set parameter No. 25 to “1.
3.6.2 Details of Input Signals Movement to each position (ST0 to ST2) When the OFF o ON rise edge of each movement signal is detected, the actuator will move to the target position corresponding to the applicable position data. Before executing a command using any of these signals, make sure the target position, speed and other operation data are set in the position table using a PC or teaching pendant.
3.6.3 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. 3. Wiring 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).
3.7 I/O Signals for PIO Pattern 0 [8 Points] Caution The factory setting is “8 points.” The pause signal can be disabled in parameter No. 15.
3.7.2 Details of Input Signals 3. Wiring Start (CSTR) When the OFF o ON rise edge of this signal is detected, the controller will read the target point number as the 3-bit binary code consisting of signals PC1 to PC4, and perform positioning to the target position specified by the corresponding position data. 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.
3.7.3 Details of Output Signals Position complete (PEND) 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.
(Reference) Output Signal Changes in Each Mode 3.
3.8 I/O Signals for PIO Pattern 2 [16 Points] (Setting by Zone Boundary Parameters) Caution The factory setting is “8 points,” so set parameter No. 25 to “2.” The pause signal can be disabled in parameter No. 15.
3.8.2 Details of Input Signals 3. Wiring Start (CSTR) When the OFF o ON rise edge of this signal is detected, the controller will read the target point number as the 4-bit binary code consisting of signals PC1 to PC8, and perform positioning to the target position specified by the corresponding position data. 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.
3.8.3 Details of Output Signals Position complete (PEND) 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.
(Reference) Output Signal Changes in Each Mode 3.
3.9 I/O Signals for PIO Pattern 3 [16 Points] (Setting in Zone Fields in the Position Table) Note The factory setting is “8 points,” so set parameter No. 25 to “3.” The pause signal can be disabled in parameter No. 15.
3.9.2 Details of Input Signals 3. Wiring Start (CSTR) When the OFF o ON rise edge of this signal is detected, the controller will read the target point number as the 4-bit binary code consisting of signals PC1 to PC8, and perform positioning to the target position specified by the corresponding position data. 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.
3.9.3 Details of Output Signals Position complete (PEND) 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.
(Reference) Output Signal Changes in Each Mode 3.
3.10 Emergency-Stop Circuit Examples of internal circuit and recommended circuit are shown below. Caution For auxiliary relays, use relays with a diode for absorbing coil surge. External EMG reset switch External EMG switch 3. Wiring Teaching pendant EMG switch Auxiliary relay Power supply Motor drive source (Rush current 6 A, rated current 2 A) [Reference] Connection detection relay Motor power supply Controller power supply Recommended relay brands are specified in the table below.
z Example of multi-axes circuit allowing each axis to be connected/disconnected to the teaching pendant External EMG reset switch 3.
3.11 Extension Cable z 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 7 AMP D-2100 6 3. Wiring 1987654321 8 5 4 3 2 (J.S.T. Mfg.) V0.5 - 3 1 100 CN1 CN2 Signal name Pin name Pin name Orange (Red 1) SGA 1 Orange (Black 1) SGB 2 1A 1B 2A 2B 3A 3B 4A 4B 5A 5B 6A 6B 7A 7B 8A 8B 9A 9B 10A 10B Wire color Housing: XMP-02V (J.S.T. Mfg.
z Connectors on both ends (When using an isolated PIO terminal block) A B B A Terminal-block end CN2 CB-ERC-PWBIO * * *-H6 (Standard cable) 10 9 Actuator end CN1 CB-ERC-PWBIO * * *-RB-H6 (Robot cable) 8 9 8 AMP 0-2100 198 76 54 3 21 7 6 5 4 3. Wiring 10 7 6 5 4 3 3 2 2 1 1 50 (J.S.T. Mfg.) V0.
4. Electrical Specifications 4.1 Controller Specification item Description 1 axis/unit Supply voltage 24 VDC r10% 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. 2 Serial E PROM can be rewritten 100,000 times.
4.2 SIO Converter (Optional) Model number: 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. [6] Monitor LEDs LED1 --- Lit when the controller is transmitting LED2 --- Lit when the RS232 is transmitting SIO converter end D-sub 9-pin, female 62 Signal No 1 RD 2 SD 3 ER 4 SG 5 DR 6 RS 7 CS 8 9 4.
4.3 Isolated PIO Terminal Block (Optional) This unit is required if either of the following conditions applies: [1] Want to insulate the control power supply from the PIO power supply. [2] Want to change the I/O logic of the control board.
[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 (RCM-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.
z Internal connection diagram [1] RCB-TU-PIO-A/B Actuator end Host system end Connector 4.
[2] PCB-TU-PIO-AP/BP Actuator end Host system end 4.
z I/O interface specifications Input Specifications Specification item Number of input points Description 6 points Input voltage r 24 VDC r 10% Input current 7 mA/circuit (bipolar) Allowable leak current ON voltage: OFF voltage: 16 V min. (4.5 mA) 5 V max. (1.3 mA) 4. Electrical Specifications Operating voltage 1 mA/point (approx.
5. Data Entry To move the actuator to a specified position, you must enter the target position in the “Position” field of the position table. The target position can be specified in two different modes: by absolute coordinate specification (absolute mode) in which the distance from the home is entered, or by relative coordinate specification (incremental mode) in which the incremental travel from the current position is entered.
(4) Acceleration/Deceleration x Enter the acceleration/deceleration at which the actuator will be moved, in [G]. Basically, you should set values within the rated range specified in the catalog. The input range is greater than the rated range in the catalog, in order to accommodate situations where you want to “shorten the tact time when the transferring mass is much smaller than the rated loading capacity.
“Push & hold operation” The set value defines the maximum distance the actuator will push the work part in the push & hold mode upon reaching the target position. Consider the mechanical variations of the work part and set an appropriate positioning band so that positioning will not complete before the actuator contacts the work part. The position complete signal turns ON here, because the actuator has contacted the load and the controller has determined that the push & hold operation has completed.
(9) Acceleration/deceleration mode This field is not used for this controller. The factory setting is “0.” (10) Incremental x This setting defines whether to use the absolute mode or incremental mode. The factory setting is “0.” 0: Absolute mode 1: Incremental mode (11) Command mode x This field is not used for this controller. The factory setting is “0.
5.
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 work part at standstill.
z Rod type (1) RA6C type (2) RA7C type Push force (N) 5.
5.2 5.2.1 Explanation of Functions Positioning Mode Push = 0 The actuator moves to the target position set in the “Position” field of the position table. Speed The position complete signal turns ON here. Target position Moving distance Time 5.2.2 Push & Hold Mode Push = Other than 0 (1) Work part was contacted successfully After reaching the target position set in the “Position” field of the position table, the actuator moves at the push speed for the distance set in the “Positioning band” field.
(2) Work part was not contacted (missed) The position complete signal will not turn ON if the actuator does not yet contact the work part after moving the distance set in the “Positioning band” field. Therefore, include a timeout check process in the sequence circuit on the PLC side. Speed If the actuator does not contact the load, the position complete signal does not turn ON. Moving distance 5.
(4) Positioning band was entered with a wrong sign If the value in the “Positioning band” field of the position table is entered with a wrong sign, the position will deviate by twice the positioning band, as shown below. Accordingly, pay due caution to the entry in this field. Speed Moving distance Positioning band Positioning band 5.2.3 Target position Speed Change during Movement Speed control involving multiple speed levels is possible in a single operation.
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. ON ON OFF *Pause signal 5. Data Entry Actuator operation Target position (Note) 5.2.
5.2.7 Home Return After the power is turned on, home return must be executed to establish the home. Upon occurrence of a cold-start level error, the power must be reconnected to restore the system. In this case, home return is also required after the reconnection of power. Which home return method is used will vary depending on the PIO pattern selected. z Home return using a dedicated input [PIO pattern = 0 (8 points)] Home return can be executed using the home return (HOME) input.
5.3 Power-saving Modes at Standby Positions One general feature of pulse motors is that their holding current in standstill state is greater than AC servo motors. Therefore, we provide energy-saving modes to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. Use these modes after confirming that they will not present problems to any part of your system. Each mode produces a different level of power-saving effect.
Full servo control mode The pulse motor is servo-controlled to reduce the holding current. Although the exact degree of current reduction varies depending on the actuator model, load condition, etc., the holding current decreases to approx. one-half to one-fourth. Since the servo remains on, no position deviation occurs. The actual holding current can be checked in the current monitor screen of the PC software.
Movement command Servo status Automatic servo-off mode (the green LED blinks) Servo on 5. Data Entry Actuator movement Target position T: Delay time after the positioning is completed until the servo turns off (sec). Position complete signal (Parameter No. 39 = 0) Position complete signal (Parameter No. 39 = 1) Setting method: Set one of the following values in the “Standstill mode” field of the position table: x Set “1”: T becomes the value of parameter No. 36.
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 actuator is used as an air cylinder. The key differences between the ERC2 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 How to Start Confirm that the connector end (CN1) of the extension cable is firmly plugged into the connector on the actuator cable. (2) Connect the PLC and the parallel I/O. (3) If the actuator has brake, set the brake release switch to OFF. (4) Supply 24 VDC to the control power supply. Cut off the motor-drive power supply (actuate an emergency stop) beforehand. (5) 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 6.3.1 Position Table and Parameter Settings Required for Operation Test Operation Immediately after the system has been started, the moving speed can be reduced by the methods specified below to ensure safety of operators and prevent damage to jigs, etc. Change the applicable parameters if necessary. o For details on the setting-change operations, refer to the operation manual for your PC software/teaching pendant. Safety speed during manual feed Parameter No.
6.3.2 Full-scale Operation We provide energy-saving modes to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. You can also select the status of position complete signal to be applied if the servo turns off or “position deviation” occurs while the actuator is standing still after completing positioning. Use these functions after confirming that they will not present problems to any part of your system.
6.4 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 6. Operation in the “3 Points (Air Cylinder)” Mode Intermediate point complete Front end complete Speed Actuator movement Mechanical Home end position Caution: 100 Rear end Intermediate point Front end [1] Movement commands are executed based on the rise edge, so input each signal continuously for 6 msec or more.
z 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 Setting 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.
z 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 Operation in the “8 Points” and “16 Points” Modes How to Start Confirm that the connector end (CN1) of the extension cable is firmly plugged into the connector on the actuator cable. (2) Connect the PLC and the parallel I/O. (3) If the actuator has a brake, set the brake release switch to OFF. (4) 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 7.2.1 Position Table and Parameter Settings Required for Operation Test Operation Immediately after the system has been started, the moving speed can be reduced by the methods specified below to ensure safety of operators and prevent damage to jigs, etc. Change the applicable parameters if necessary. o For details on the setting-change operations, refer to the operation manual for your PC software/teaching pendant. Safety speed during manual feed Parameter No.
7.2.2 Full-scale Operation We provide energy-saving modes to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. You can also select the status of position complete signal to be applied if the servo turns off or “position deviation” occurs while the actuator is standing still after completing positioning. Use these functions after confirming that they will not present problems to any part of your system.
7.3 How to Execute Home Return First, force the position complete signal to turn ON by referring to 7.1, “How to Start.” 7.3.1 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 Home return completion HEND Actuator movement Mechanical end Caution: 98 Stops at the home position. When the home return signal turns ON, the position complete output will turn OFF.
7.3.2 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.
7.4 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 Speed Home return completion Positioning band Actuator movement Time 7. Operation in the “8 Points” and “16 Points” Modes 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.
7.5 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. 0 Position [mm] * Speed [mm/s] * Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 1 250.00 200.00 0.30 0.30 0 0.10 2 100.00 100.00 0.30 0.30 0 0.10 x x x Start Position 2 Position 1 Command position T1 T1 Position 1 T1 T1 Speed 7.
7.6 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 work part and push it in the counter-motor direction).
Position-data table (Field(s) within thick line must be entered.) No. 0 Position [mm] * Speed [mm/s] * Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 1 280.00 200.00 0.30 0.30 50 15.00 2 40.00 100.00 0.30 0.30 0 0.10 x x x Command position Position 1 T1 Start Position 2 T1 Position 1 T1 Speed Position complete 7.
7.6.1 Notes on Returning in the Incremental Mode after Push & Hold Operation The reference position to be used when the actuator returns after push & hold operation is different between the positioning mode and the push & hold mode (the work part was missed). z Positioning mode The reference position is the target position for the position number used in the applicable push & hold operation. In the aforementioned example, the actuator moves to the 240-mm position if position No.
7.7 Speed Change during Movement Example of use in operation) Method) 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. 0 Position [mm] * 1 150.00 2 200.00 Speed [mm/s] * 200.00 100.00 Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 0.30 0.30 0 10.00 0.30 0 0.10 0.30 x x x Command position Position 1 T1 Start Position 2 T1 Note Note Speed 7.
7.8 Operation at Different Acceleration and Deceleration Settings In applications where the work part or peripheral equipment should not receive impact or vibration when the actuator is standing still, you can apply a gradual curve only during deceleration. Example of use in operation) Move the actuator from the home to the 150-mm position (position 1) at a speed of 200 mm/sec. The acceleration and deceleration are to be 0.3 G and 0.05 G, respectively. Method) Set “0.
Position-data table (Field(s) within thick line must be entered.) No. 0 Position [mm] * 1 150.00 Speed [mm/s] * 200.00 Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 0.30 0.05 0 0.10 x x x Command position Start Position 1 T1 Positioning band Actuator movement Acceleration 0.3G T1: 7. Operation in the “8 Points” and “16 Points” Modes Speed Position complete Deceleration 0.
7.9 Pause Example of use in operation) Method) The actuator is paused during movement. Use the pause input. ERC2 controller Reference flow PIO Signal name P [4] [2] Category [1] Select/enter a desired command position. [2] Start input ON Start Command position 1 7. Operation in the “8 Points” and “16 Points” Modes [1] Command position 2 Command position 4 L Movement to the selected position starts.
Command position T1 Start Note Position complete Speed Pause Actuator movement T1: 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.) Caution: 112 Start of remaining movement 7. Operation in the “8 Points” and “16 Points” Modes Deceleration to a stop When the start signal turns ON, the position complete output will turn OFF.
7.10 Zone Signal How the boundaries are set varies depending on the PIO pattern. x If fixed boundaries are applied to all operations, set them using parameters. (PIO pattern = 0 or 2). x To set different boundaries for each position number to support multiple loads, set respective settings in the position table. (PIO pattern = 3) Example of use in operation) Method) Output a zone signal in a range of 40 to 120 mm while the actuator is moving from the home to the 150-mm position (position 1).
Command position Start T1 Note Position complete Speed Zone Actuator movement T1: 120 mm 7. Operation in the “8 Points” and “16 Points” Modes 40 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.) Caution: When the start signal turns ON, the position complete output will turn OFF.
7.11 Incremental Moves Example of use in operation) Move the actuator from the home to the 30-mm position (position No. 1) set in the absolute mode, and then move the actuator further through continuous incremental moves at a 10-mm pitch until the final position of 200 mm is reached. (Pitch feed is specified by position No. 2.) ERC2 controller Reference flow PIO Signal name P [9] [7] [4] [2] 7.
Position-data table (Field(s) within thick line must be entered.) No. 0 1 2 x x x * = Position [mm] * 30.00 10.00 Speed [mm/s] * 100.00 20.00 Positioning band [mm] * 0.10 0.10 Zone+ [mm] * 0 190.50 Zone[mm] * 0 29.50 Incremental * 0 1 Incremental moves On the teaching pendant screen, this sign indicates that the position is specified in the incremental mode.
7.11.1 How to Determine the Final Position 7. Operation in the “8 Points” and “16 Points” Modes The PLC manages the number of movements to determine the end of positioning. To be doubly sure, the zone output signal can also be used concurrently. Set the PLC so that it checks the ON/OFF status of the zone output signal upon completion of positioning, and determines, if the signal is OFF, that the last work part has been reached.
7.12 Notes on Incremental Mode (1) Positioning mode Selecting/entering a position number in the incremental mode 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.
(2) Push & hold mode The following explains how the actuator will behave when a start signal is input after selecting/entering a position number in the incremental mode while the actuator is moving in the push & hold mode.
z Moving in the push & hold mode to the position number set in the incremental mode Example) If a start signal is input to initiate positioning to position 2 while the actuator is moving to position 1, the actuator will move to a new target position, which is determined by adding the increment to the position at which the start input was received. Since the target position is indeterminable, never use this method. Position-data table (Field(s) within thick line must be entered.) No.
8. 8.1 Parameter Settings Parameter Table 8. Parameter Settings 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 No.
8.2 Detailed Explanation of Parameters If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power. 8.2.1 Parameters Relating to the Actuator Stroke Range z 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.
z Home return offset The controller is shipped from the factory with an optimal value set in parameter No. 22, so the distance from each mechanical end to the home becomes uniform. The minimum setting unit is “0.01 [mm].
8.2.2 Parameters Relating to the Actuator Operating Characteristics z Default speed The factory setting is the rated speed of the actuator. When a target position is set in an unregistered position table, the setting in this parameter will be used as the speed data for the applicable position number. To reduce the default speed from the rated speed, change the setting in parameter No. 8. z Default acceleration/deceleration The factory setting is the rated acceleration/deceleration of the actuator.
z Default direction of excited-phase signal detection When the servo is turned on for the first time after a power on, excited phase is detected. This parameter defines the direction of this detection. The parameter need not be changed in normal conditions. In certain situations, such as when the actuator was contacting a mechanical end or obstacle when the power was turned on and cannot be moved by hand, change the direction that allows the motor to operate smoothly. To do this, set parameter No.
z Automatic servo-off delay time This parameter defines the delay time after the positioning is completed until the servo turns off automatically, when the “Standstill mode” field of the position table is set to 1, 2 or 3 (automatic servo-off control enabled) or parameter No. 53 (Default standstill mode) is set to 1, 2 or 3 (automatic servo-off control enabled). Meaning of settings: 1: T becomes the value set in parameter No. 36. 2: T becomes the value set in parameter No. 37.
z Push speed This parameter defines the push speed to be applied after the actuator reaches the target position in push & hold operation. Before the shipment, this speed has been set to a default value appropriate for the characteristics of the actuator. Set an appropriate speed in parameter No. 34 by considering the material and shape of the work part, and so on. Take note that the maximum speed is limited to 20 [mm/sec] even on high-speed types. Use the actuator at push speeds not exceeding this level.
8.2.3 Parameters Relating to the External Interface z 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. Setting of parameter Feature of the PIO pattern No. 25 0 8 points The basic pattern providing eight positioning points. 1 3 points (air cylinder) This pattern assumes that the actuator is used in place of an air cylinder.
[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) 8. Parameter Settings Position complete (PE0 to PE2) Actuator movement Target position z Pause input disable selection Parameter No. 15 defines whether the pause input signal is disabled or enabled.
z Output mode of position complete signal This parameter defines the status of position complete signal to be applied if the servo turns off or “position deviation” occurs while the actuator is standing still after completing positioning. The following two conditions can be considered: [1] The position has deviated, due to external force and while the servo was on, beyond the value set in the “Positioning band” field of the position table.
z Silent interval multiplication factor 8. Parameter Settings This parameter is not used for this controller. It is applied to controllers of RS485 serial communication type. If specified, this parameter defines the multiplication factor to be applied to the silent interval time for delimiter judgment in the RTU mode. The default setting is the communication time corresponding to 3.5 characters in accordance with the Modbus specification.
8.2.4 Servo Gain Adjustment Before the shipment, the servo has been adjusted in accordance with the standard specification of the actuator. Accordingly, the servo settings need not be changed in normal conditions. Nonetheless, the parameters relating to servo adjustment are made accessible by the customer so that speedy actions can be taken in situations where vibration or noise occurs due to the affixing method of the actuator, load condition, or the like.
z Speed loop integral gain Parameter No. 32 Unit --- Input range Default 1 ~ 217270 Set individually in accordance with the actuator characteristics. This parameter is used to determine the response of the speed control loop. Reducing the set value lowers the response to speed commands, meaning that the reactive force that generates in response to load change becomes smaller. A smaller set value also results in poorer compliance with position commands, causing the positioning time to become longer.
9. 9.1 Troubleshooting 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. 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.
9.2 Alarm Level Classification Alarms are classified into two levels according to the symptoms they represent. Alarm level LED color Operation cancellation Cold start (Note) 9.2.1 *ALM signal Red OFF Red OFF What happens when alarm generates The actuator decelerates to a stop and then the servo turns OFF. The actuator decelerates to a stop and then the servo turns OFF. How to reset See below. Reconnect the power or reset the software. The *ALM output signal is a contact-b signal.
9.3 Alarm Description and Cause/Action (1) Operation-cancellation level alarms Code Error name Cause/Action A1 Parameter data error Cause: The parameter data does not meet the specified input range. (Example) This alarm generates when a pair of values clearly has an inappropriate magnitude relationship, such as when the soft limit + setting is 200.3 mm, while the soft limit – setting is 300 mm. Action: Change the settings to appropriate values.
Error name Cause/Action C9 Excessive motor supply voltage This alarm indicates that the motor supply voltage is excessive (24 V + 20%: 28.8 V or more). Cause: [1] High voltage of the 24-V input power supply [2] Faulty internal part of the controller Action: Check the voltage of the input power supply. If the voltage is normal, please contact IAI. CA Overheating The temperature around the power transistor in the controller is too high (95qC or above).
(2) Cold-start level alarms Code Error name Cause/Action Excitation detection error This controller detects excited phase when the servo is turned on for the first time after a power on. This alarm indicates that the specified encoder signal level cannot be detected after the specified period of excitation. Cause: [1] Loose or disconnected connector of the motor extension cable [2] The brake cannot be released (if the actuator is equipped with a brake).
Error name F5 Verification error of data written to nonvolatile memory When data was written to the nonvolatile memory, the written data is read and compared (verified) against the original data. This alarm indicates that the read data does not mach the original data written. Cause: [1] Faulty nonvolatile memory [2] The memory has been rewritten more than 100,000 times. (As a rough guideline, the nominal service life of the nonvolatile memory is 100,000 rewrites.
9.4 Messages Displayed during Operation Using the Teaching Pendant This section explains the warning messages that may be displayed during operation using the teaching pendant. Code Error name Cause/Action Invalid data An inappropriate value was entered in a parameter. (Example) 9601 was entered as the serial communication speed by mistake. Enter an appropriate value again. 113 114 Value too small Value too large The entered value is smaller than the setting range.
9. Troubleshooting 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.
9.5 Specific Problems z I/O signals cannot be exchanged with the PLC. Cause: [1] The 24-V I/O 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, a circuit component may have been damaged due to a large load that caused the current flowing into the circuit to exceed the maximum level. [3] Contact failure in the connector or relay terminal block on the PLC end.
z Noise occurs during downward movements in a vertical application. Cause: The load exceeds the rating. Action: [1] Decrease the speed. [2] Decrease the value set in the user parameter No. 7 (Servo gain number). Do not decrease the parameter setting below “3.” z 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.
10. Maintenance and Inspection 10.1 Inspection Items and Schedule 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 SA6C and SA7C, the screw cover and side covers can be removed using a hex wrench with 1.5 mm width across flats. x The front and rear brackets are supporting the ball screw, so do not disassemble these brackets. x Precision instrument is assembled into the motor cover, so do not disassemble the motor cover. 10. Maintenance and Inspection [2] Visually check the internal condition.
10.5 Internal Cleaning (Slider Type) x x x 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. Caution: 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. 10. Maintenance and Inspection [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: Never use fluorine grease. If fluorine grease is mixed with lithium grease, the grease function will drop and it causes damage to the mechanism.
10.8 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 10. Maintenance and Inspection Use lithium grease for maintenance. Note: Never use fluorine grease. If fluorine grease is mixed with lithium grease, the grease function will drop and it causes damage to the mechanism. Caution: In case the grease got into your eye, immediately go to see the doctor to get an appropriate care.
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: x Save the data to a file using the PC software. x Prepare position/parameter tables and manually write the values. When a new motor has been installed, enter the parameter/position data to the controller.
x 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. Motor unit 10.
Appendix 11. Appendix . External Dimensions . . ERC -SA C 60 50 5 4-M5 Depth 10 9 32p 0.02 9 (300) Cable joint connector (Reamer Pitch Tolerance p0.02) 22 31 37.4 5 Ma Moment Offset Datum Position Stroke 60 Home S.E. 50.9 13.5 2.5 M.E.*2 S E : Stroke End ME : Mechanical End Teaching Port 118.5 Secure at least 100 PIO type (6) 25 58 (6) S-4.5 Drilled Hole, F 8 Counter Boring Depth 4.5 55 Part A 25 37.5 49.1 2.3 M.E. L 36 80.6 59 50 48.
Appendix ERC -SA C * . . Appendix 75 Example of Basic ERC2 Positioning Sequence 5 65 5 32 40 47.4 4-M5 Depth 10sequence using the Given below is an example of basic sequence for creating (300)ERC2. 9 47 p0.02 9a positioning Cable joint indicates PIO signals of the ERC2 controller. connector L Home S.E. 55.2 16 2.5 Ｍ.E.*2 Teaching Port 118.5 46 Home return request S-4.5 Drilled Hole, F 8 Counter Boring Depth 4.5 Secure at least 100 68 4 C F4.
Appendix ERC -RA C * . . Appendix 2 Example of Basic ERC2 Positioning Sequence Home M.E. (300) Cable joint Given below is an example of basic sequence for creating a positioning sequence using the ERC2. connector indicates PIO signals of the ERC2 controller. Home return request StrokeB Rod Diameter F 22 Home return request B A 7 2 18 31.7 49.7 C 8 A HOME ac tf fla ) 1 es 44 54 58 D C 43.5 118.5 Brake unit HEND D Stroke 50 100 150 200 250 300 L 293.5 343.5 393.5 443.5 493.5 543.
Appendix ERC -RA C * . . Appendix 4 Example of Basic ERC2 Positioning Sequence Home M.E. (300) Given below is an example of basic sequence for creating a positioning sequence using the Cable ERC2.joint connector indicates PIO signals of the ERC2 controller. Home return request StrokeB L B A : Mechanical End M.E. Teaching Port A B A 9 21 2 40 61 20 Rod Diameter F 30 Home return request A PIO type Secure at least 100 32 1 ) es ac HEND D C 7 tf fla C 50 64 68 49 118.
Appendix ERC -RGS C * . . Appendix Example of Basic ERC2 Positioning Sequence Home B 20 23.7 8 55 ST 3.3 10 40 54 91 57 13 37 B 24 C HOME 3 3 54 Home return signal HOME 7 A F10 22.5 Home return request 106.5 ST 58.3 A 12.5 12.5 20 51.7 ME : Mechanical End 6-M5 30 A B M.E. ST 52 A 2 F34 Home return request 54 Given below is an example of basic sequence for creating a positioning sequence using the ERC2. indicates PIO signals of the ERC2 controller.
Appendix ERC -RGD C * . . Appendix 53 Example of Basic ERC2 Positioning Sequence 52 Given below is an example 42 of basic sequence for creating a positioning sequence using the ERC2. indicates PIO signals30of the ERC2 controller. 20 54 Home return request B B ME : Mechanical End 55 C ST 3.3 Home return signal HOME 54 A 20 23.7 8 F10 134 159 A 114 54 145 8-M5 F34 13 B A A 4-M5 114 Home return request HOME 2 M.E. 51.7 Home HEND H 63 62 52 34 25 I 50 0.4 2.0 100 0.4 2.
Appendix 11.2 Example of Basic ERC2 Positioning Sequence Given below is an example of basic sequence for creating a positioning sequence using the ERC2. indicates PIO signals of the ERC2 controller.
Appendix (Positioning circuit for position 2) Positioning start request to position 2 M N Positioning start request to position 2 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 N M P O O PEND Q P P PEND If a measure is taken to identify the current position in the sequence in case the sequ
Appendix R PC1 Command position 1 PC2 Command position 2 PC4 Command position 4 Timer 2 Waiting for start Position 3 set signal Position 5 set signal S Position 3 set signal Position 6 set signal 11. Appendix (Start signal circuit) J O Start command for positioning to other position 5 msec or more (Must be longer than the PLC’s scan time.
170 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 No. Speed [mm/s] Acceleration Deceleration [G] [G] Recording of Position Table Position [mm] 11.3 Push [%] Threshold [%] Positioning Zone+ band [mm] [mm] 11.
Appendix 11.4 Parameter Records Category: a: b: c: d: Recorded date: Parameter relating to the actuator stroke range Parameter relating to the actuator operating characteristics Parameter relating to the external interface Servo gain adjustment No.
Change History Revision Date January 2011 Description of Revision Third edition Added “Before Use.” Changed “Safety Precautions” to “Safety Guide.” P. 6: Added 1.3.3, “The sound pressure level of this product does not exceed 70 dB.” P. 13: Moved “Prohibitions/Notes on Handling Cables” to after 1.7, “Wiring.” P. 133: Changed the description relating to the speed loop integral gain. April 2011 Fourth edition A page for CE Marking added March 2012 Fifth edition Change History P.
Manual No.: ME0158-5A (March 2012) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W.
