RCP2 Series ROBO Cylinder Controller Operation Manual Sixteenth Fifteenth 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. 24-V Power Supplies for Equipment Requiring a UL Certification [1] [2] 2. The controller with the maximum current of 2 A (RCP2-C/CG) and 6 A (RCP2-CF) are UL-certified. However, a UL certification requires that the 24-V power supplies used with the controller conform to Class 2. If the user’s equipment must receive a UL certification, please use an input power supply and an I/O power supply both conforming to Class 2. RCP2 controller can be used in the environment of the pollution degree 2.
[2] Enabling/disabling the servo ON input signal (SON) The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side. Depending on the needs, therefore, the user must enable/disable this signal. To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection). Enable (use) the signal 0 Disable (do not use) the signal 1 If “0” or “2” has been selected as the above PIO pattern, the servo ON signal is not provided.
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. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 3.4 4. 4.1 4.2 4.3 Overview ..............................................................................................1 Introduction..................................................................................................................................... 1 How to Read Model Number.........................
4.4 4.5 5. 5.1 5.2 5.3 PIO pattern 3 [2 zone output signals].................................................................................... 35 PIO pattern 4 [Teaching]........................................................................................................ 36 PIO pattern 5 [4 points] (air cylinder)..................................................................................... 37 Connecting the Actuator......................................................................
6. 6.1 6.2 6.3 7. Data Entry ..........................................................................56 Description of Position-Data Table ............................................................................................... 57 6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value.................................... 60 (1) SA5/SA6/SS type (2) SA7 type ............................................................................................. 60 (3) SM type ....
Soft limit............................................................................................................................... 110 Zone boundary .................................................................................................................... 110 Home return direction...........................................................................................................111 Home return offset............................................................................
Noise occurs during downward movements in a vertical application.................................. 134 Vibration occurs when the actuator is stopped. .................................................................. 134 The actuator overshoots when decelerated to a stop. ........................................................ 134 The home and target positions sometimes shift..................................................................
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 Installation of railings, enclosures, etc. Cut off (including Sign, etc., indicating that work is in stopping of operation) 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.
Pre-8
1. 1.1 Overview Introduction Thank you for purchasing the RCP2 controller. This manual explains the features and operating procedures of the product. If not used or handled properly, even a brilliant product cannot fully demonstrate its function or may cause an unexpected breakdown or end its life prematurely. Please read this manual carefully and handle the product with utmost care while ensuring its correct operation.
1.
1.3 Handling of Secondary Batteries for the Absolute Specification Observe the safety precautions specified below when handling the secondary batteries: 1. Never attempt to disassemble the batteries. Strong alkali battery fluid will damage the skin or clothes. 2. Never short the battery terminals (i.e. by allowing the positive and negative terminals to make direct contact). Doing so may damage the equipment or cause burns due to the generation of heat. 3.
1.4 Safety Precautions Read the following information carefully and provide safety measures with due consideration. This system product has been developed as a drive component for automated machinery and the like, and is therefore designed not to generate excessive torque or speed beyond the levels needed to drive automated equipment. However, the following instructions must be strictly observed to prevent an unexpected accident. 1. Do not handle this product in any manner not specified in this manual.
1.5 Warranty Period and Scope of Warranty The RCP2 controller you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The unit is covered by the following warranty: 1. Warranty Period The warranty period shall be one of the following periods, whichever ends first: 18 months after shipment from our factory 12 months after delivery to a specified location 2.
2. Specifications 2.1 Basic Specifications Specification item Internal Drive-Power Cutoff Relay Type RCP2-C-*** (Note) External Drive-Power Cutoff Relay Type RCP2-CG-*** Number of controlled axes 1 axis/unit Supply voltage 24 VDC 10% Supply current 2 A max.
2.1.1 Backup Batteries for the Absolute Specification The absolute-specification controller uses secondary batteries (nickel metal hydride cells) to retain absolute counter data in the FPGA (field-programmable gate array) after the power is cut off, and also to supply power to the encoder’s drive circuit intermittently.
2.1.2 Specifications of the Large-Capacity Type (RCP2-CF) Specification item Internal Drive-Power Cutoff Relay Type Model number RCP2-CF-*** Number of controlled axes 1 axis/unit Supply voltage 24 VDC 10% Supply current 6 A max.
2.2 Name and Function of Each Part of the Controller 2.2.1 Names [1] Battery connector (absolute specification) [2] Status indicator LEDs RDY (green) RUN (green) ALM (red) [3] PIO pattern number label [4] Teaching pendant/ PC connector [7] I/O signal connector [8] Address switch [9] PORT switch [10] Encoder connector [11] Brake release switch [5] [6] 2.2.
[5] Motor connector (MOT) A connector for the actuator’s motor power cable. [6] Power/emergency-stop terminal block [Built-in cutoff relay type RCP2-C, RCP2-CF] S1, S2 MPI, MPO 24V N EMG Provide a contact output for the emergency-stop button on the teaching pendant. Port switch ON = Emergency-stop button output (Contact B) Port switch OFF = ON in normal conditions of use (Emergency-stop button output is disabled) Provide a contact for cutting off the motor drive power.
2.3 2.3.1 External Dimensions Standard Specification (RCP2-***-I ) (Mounting dimension) An external view and dimensions of the product are shown below.
2.3.
Absolute Specification without Battery Bracket ) (Mounting dimension) (RCP2-***-A- *Weight: 460 g 13
Large-Capacity Type (RCP2-CF-***) (Mounting dimension) 2.3.
3. Installation and Noise Elimination Pay due attention to the installation environment of the controller. 3.1 Installation Environment (1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient ventilation will not only prevent the controller from demonstrating its full performance, but it may also cause breakdown.) (2) Prevent foreign matter from entering the controller through the ventilation holes.
[2] Precautions regarding wiring method Use a twisted cable for connection to the 24-VDC external power supply. Separate the controller cables from high-power lines such as a cable connecting to a power circuit. (Do not bundle together the controller cables with high-power lines or place them in the same cable duct.) When extending the supplied motor cable or encoder cable, consult IAI’s Technical Support.
3.4 Heat Radiation and Installation Design the control panel size, controller layout and cooling method in such a way that the temperature around the controller will not exceed 40C. Install the controller vertically on a wall, as shown below. Since cooling is provided by way of natural convection, always observe this installation direction and provide a minimum clearance of 50 mm above and below the controller to ensure sufficient natural airflows.
4. Wiring 4.1 Internal Drive-Power Cutoff Relay Type (RCP2-C, RCP2-CF) 4.1.1 Configuration Host system Standard teaching pendant Optional Cable length: 5 m Supplied flat cable Cable length: 2 m * If the PLC is not used, disable the servo ON input and pause input using the applicable parameters.
4.1.2 External Connection Diagram An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable for the controller with the maximum current of 2 A. As for the robot cable or the cable for the large-capacity type, refer to 4.4.2, “Encoder Extension Cable.
4.1.3 (1) Wiring the Power Supply/Emergency-Stop Switch Wiring the power supply Input power supply 24 VDC (2 A max. per controller) S1 S2 MPI MPO 24V N EMG 24V 0V FG To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications: Item Specification Applicable wire length Single wire: 1.0 / Stranded: 0.
(2) Wiring the emergency-stop switch In many cases multiple controllers are used in a single system. To provide an emergency-stop function for the entire system, the controller circuit is designed in such a way that a single EMG switch is able to actuate an emergency stop in all connected controllers. [Internal emergency-stop circuit] Teaching pendant ON EMG signal OFF PORT switch S1 S2 Relay MPI Input power supply (C: 2 A max.) (CF: 6 A max.
Representative connection examples are explained below. Connecting the teaching pendant directly to the controller (Parallel connection with the PLC) [1] Connecting multiple controllers (8 units or less) using a single power supply Short the MPI and MPO terminals using a jumper wire. (The controller is shipped with these terminals shorted.) Connect one end of the EMG signal to the 24-V output of the input power supply and the other end to the S1 terminal.
[Controller 1] 24V Teaching pendant EMG signal S1 0V S2 ON MPI MPO 24V OFF PORT switch N Relay EMG [Controller 2] Teaching pendant S1 S2 ON MPI MPO 24V OFF PORT switch N Relay EMG [Controller 3] Teaching pendant S1 S2 ON MPI MPO 24V OFF PORT switch N Relay EMG [Controller 4] Teaching pendant S1 S2 ON MPI MPO 24V OFF PORT switch N Relay EMG 23
[2] Using a power supply other than the input power supply (Note) Since the controller’s PORT switch has a cutoff capacity of 0.1 A, use an auxiliary relay with a coil current of 0.1 A or less and connect a diode for coil surge absorption.
[3] Enabling the EMG switch on the teaching pendant for the connected axis or axes only 24V 0V EMG signal CR [Controller 1] Teaching pendant CR S2 S1 ON MPI MPO 24V OFF PORT switch N Relay EMG [Controller 2] Teaching pendant S2 S1 ON MPI MPO 24V OFF PORT switch N Relay EMG [Controller 3] Teaching pendant S2 S1 ON MPI MPO 24V OFF PORT switch N Relay EMG 25
Connecting the teaching pendant to a SIO converter (Serial connection with the PLC) Configure the contact circuit for the EMG switch on the teaching pendant using EMG1/EMG2 on the power/emergency-stop terminal block on the SIO converter. (S1/S2 on the controller’s terminal block are not used.
4.2 4.2.1 External Drive-Power Cutoff Relay Type (RCP2-CG) Configuration Host system Standard teaching pendant Optional Cable length: 5 m Supplied flat cable Cable length: 2 m * If the PLC is not used, disable the servo ON input and pause input using the applicable parameters.
4.2.2 External Connection Diagram An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable. As for the robot cable, refer to 4.4.2, “Encoder Extension Cable.” Controller (PORT switch) Connected to teaching pendant or PC Terminal block Motor drivepower cutoff circuit Actuator Input power supply 24V 24 VDC 0V FG Blue Black Host system White Red Black Green Motor flat cable Yellow Orange (black 2) Orange (red 2) Refer to 4.
4.2.3 (1) Wiring the Power Supply/Motor Power Cutoff Relay Wiring the power supply Input power supply 24 VDC (2 A max. per controller) S1 S2 MPI MPO 24V N FG 24V 0V FG To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications: Item Specification Applicable wire length Single wire: 1.0 / Stranded: 0.
(2) Wiring the motor power cutoff relay Explained below is a safety circuit conforming to safety category 2. The user is responsible for implementing additional safety measures in the actual circuit configuration, such as providing double contactor contacts to prevent fusing. The circuit illustrated below is for reference purposes only. The input side of the motor drive power supply is connected to the MPI terminal, while the output side is connected to the MPO terminal.
[Connection example of a multiple-axis configuration] Input power supply 24V 0V FG Connect to 24-V terminal Connect to N terminal Connect to FG terminal [Controller 1] [Controller 2] [Controller 3] S1 S2 S1 S2 S1 S2 MPI MPO 24V N FG MPI MPO 24V N FG MPI MPO 24V N FG EMG signal Contactor External reset switch S33 S34 S11 S12 13 23 33 Safety relay unit Phoenix contact (PSR-SCP-24UC-/ESA2/4X1/1X2/B) A1 A2 14 24 34 31
4.
PIO pattern 1 [Standard] Controller end PIO (signal abbreviation) Host system end Upper stage +24 [V] 0 [V] Command position 1 Command position 2 Output side Command position 4 Command position 8 Brown 1 Red 1 Start Home return Servo ON Reset Yellow 1 Green 1 Blue 1 Gray 1 White 1 Black 1 Brown 2 Red 2 Orange 2 Lower stage Yellow 2 Green 2 Blue 2 Completed position 1 Purple 2 Completed position 2 Gray 2 Completed position 4 White 2 Input side Completed position 8 Zone output Moving Pos
PIO pattern 2 [64-point positioning] Host system end +24 [V] 0 [V] Command position 1 Command position 2 Output side Command position 4 Command position 8 Command position 16 Command position 32 Start Home return Pause Reset Upper stage Brown 1 Red 1 Orange 1 Yellow 1 Green 1 Blue 1 Purple 1 Gray 1 White 1 Black 1 Brown 2 Red 2 Orange 2 Lower stage Yellow 2 Green 2 Completed position 1 Completed position 2 Blue 2 Purple 2 Gray 2 Completed position 4 White 2 Input side Completed position 8
PIO pattern 3 [2 zone output signals] Host system end +24 [V] 0 [V] Command position 1 Command position 2 Output side Command position 4 Command position 8 Upper stage Brown 1 Red 1 Orange 1 Yellow 1 Green 1 Blue 1 Purple 1 Pause Start Home return Servo ON Reset Gray 1 White 1 Black 1 Brown 2 Red 2 Orange 2 Lower stage Yellow 2 Green 2 Blue 2 Completed position 1 Purple 2 Completed position 2 Completed position 4 Gray 2 White 2 Input side Completed position 8 Zone output 1 Zone output 2
PIO pattern 4 [Teaching] Controller end PIO (signal abbreviation) Host system end Upper stage +24 [V] Brown 1 Red 1 0 [V] Orange 1 Command position 1 Yellow 1 Command position 2 Green 1 Command position 4 Blue 1 Output side Command position 8 Purple 1 Operation mode Gray 1 Pause/+Jog White 1 Start/Position write Black 1 Home return Brown 2 Servo ON Red 2 Reset/–Jog Lower stage Orange 2 Yellow 2 Green 2 Blue 2 Completed position 1 Purple 2 Completed position 2 1A P24 2A N
PIO pattern 5 [4 points] (air cylinder) Host system end +24 [V] 0 [V] Output side Rear end move Front end move Intermediate point 1 move Intermediate point 2 move Pause Upper stage Brown 1 Red 1 Orange 1 Yellow 1 Green 1 Blue 1 Purple 1 Gray 1 White 1 Black 1 Brown 2 Reset Red 2 Orange 2 Lower stage Yellow 2 Green 2 Rear end complete Input side Front end complete Intermediate point 1 complete Intermediate point 2 complete Zone output Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Position
4.4 Connecting the Actuator 4.4.1 Motor Extension Cable Connect the motor extension cable to the MOT connector. Signal table for the controller-end connector (CN2) Pin No.
4.4.2 Encoder Extension Cable [Standard controller (2 A)] Connect the encoder extension cable to the ENC connector. Signal table for the controller-end connector (CN2) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal abbreviation F.
Reference: Cable colors and pin assignments for units shipped on or before July 31, 2004 Controller end Actuator end CN2 pin assignments CN1 pin assignments 2 15 16 1 10 9 18 CN1 CN2 1 Standard cable Robot cable CB-RCP2-PA * * * CB-RCP2-PA * * *-RB CN2 Cable color Robot cable Light blue (red 1) Light blue (black 1) White (red 1) White (black 1) Yellow (red 1) Yellow (black 1) Orange (red 2) Orange (black 2) Ground Signal Pin No.
[Large-capacity controller (6 A)] Connect the encoder extension cable to the ENC connector. Signal table for the controller-end connector (CN2) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal abbreviation F.
4.5 Connecting the Communication Cable Connect the communication cable to the SIO connector. Pin assignments of the cableend connector Controller end RS485 conversion adapter end CB-RCA-SIO * * * Signal abbreviation Pin No. Pin No.
5. I/O Signal Control and Signal Functions 5.1 PIO Patterns and Signal Assignments This controller provides six PIO (Parallel I/O) patterns to meet the needs of various applications. To select a desired PIO pattern, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern selection). The features of each PIO pattern are explained below: Parameter No. 25 setting 0 1 2 3 4 5 Feature of PIO pattern Conventional This pattern is compatible with the pin assignments of the RCP controller.
5.1.1 Explanation of Signal Names The following explains the signal names, and gives a function overview of each signal. In the explanation of operation timings provided in a later section, each signal is referenced by its selfexplanatory name for clarity. If necessary, however, such as when marker tubes are inserted as a termination of the flat cable, use the signal abbreviations.
PIO pattern = “4: [Teaching]” Category Input Output Signal name Signal abbreviation Function overview Start CSTR Movement is started at a rise edge of this signal. Command position number PC1 PC2 PC4 PC8 The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON. *Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a stop Home return HOME Home return operation is started at a rise edge of this signal.
PIO pattern = “5: [4 points] Category Input Output 46 Signal name Signal abbreviation Function overview Rear end move ST0 The actuator starts moving to the rear end at the rise edge of the signal. Front end move ST1 The actuator starts moving to the front end at the rise edge of the signal. Intermediate point 1 move ST2 The actuator starts moving to intermediate point 1 at the rise edge of the signal.
5.1.2 Signal Assignment Table for Respective PIO Patterns The same signal may be assigned to a different pin number depending on the PIO pattern. Therefore, when creating a PLC sequence or wiring the signals, refer to this table to ensure each signal is assigned correctly. When “4: [Teaching]” is selected, the meaning of each pin number will vary depending on the mode. Accordingly, also pay due attention to when mode switching will occur. Pin No. Category Parameter No.
5.2 Interface Circuit The standard interface specification of the controller is NPN, but the PNP specification is also available as an option. To prevent confusion during wiring, the NPN and PNP specifications use the same power line configuration. Accordingly, there is no need to reverse the power signal assignments for a PNP controller. 5.2.
5.2.
5.3 Details of I/O Signal Functions An input time constant is provided for the input signals of this controller, in order to prevent malfunction due to chattering, noise, etc. Except for certain signals, switching of each input signal will be effected when the signal has been received continuously for at least 6 msec. For example, when an input is switched from OFF to ON, the controller will only recognize that the input signal is ON after 6 msec.
Home return (HOME) The controller will start home return operation upon detection of an OFF ON edge of this signal. When the home return is complete, the HEND signal will be output. The HOME signal can be input as many times as required. (Note) The HOME signal is not an absolute requirement, because even if home return has not yet been performed after the power was input, the controller will automatically perform home return operation before positioning to the target position. Setting “0.
Current-position write (PWRT) This signal is enabled when the aforementioned MODES output signal is ON. If the PWRT signal has remained ON for 20 msec or longer, the controller will read the position number specified by the currently detected binary code consisting of PC1 to PC8, and write the current position data as the target position in the corresponding position data. If data other than the target position (speed, acceleration/deceleration, positioning band, etc.
5.3.2 Details of Each Output Signal Completed position number (PM1 to PM32) These signals can be used to check the completed position number when the PEND signal turns ON. The signals are output as a binary code. Immediately after the power is input, all of the PM1 to PM32 signals are OFF. (Only with an expanded controller the binary code consists of six bits from PM1 to PM32. The binary code for all other controller types consists of four bits from PM1 to PM8.
Once turned ON, the HEND signal will not turn OFF unless the input power supply is cut off, a soft reset is executed, or the home return signal is input again.
Ready (SRDY) This is a monitor signal indicating that the servo is ON and the motor is ready. The ON/OFF status of the SRDY signal is synchronized with the lit/unlit status of the “RUN” LED on the front panel of the enclosure. Use this signal as a condition for starting a movement command on the PLC side. Refer to 7.1, “How to Start,” for the timing to issue this signal after the power is input.
6. Data Entry This controller 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.
6.1 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 [%] In the push & hold mode, enter the current-limiting value for the pulse motor during push & hold operation. (5) Push (Push) Be sure to refer to 6.1.
(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. The deceleration conforms to the value entered in (4).
6.1.1 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.
(3) SM type Push force (N) Low-speed type (Lead: 5 mm) Current-limiting value (ratio in %) Push force (N) Medium-speed type (Lead: 10 mm) Current-limiting value (ratio in %) High-speed type Push force (N) (Lead: 20 mm) Current-limiting value (ratio in %) Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc.
Rod type (1) RPA type (2) RXA type Push force (N) Push force (N) Low-speed type (Lead: 2.5 mm) Current-limiting value (%) Current-limiting value (%) Push force (N) Medium-speed type (Lead: 5 mm) Current-limiting value (%) Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.
(3) RSA/RSW type (4) RMA/RMW type Low-speed type (Lead: 4 mm) Push force (N) Push force (N) Low-speed type (Lead: 2.
(5) RFA/RFW type Push force (N) Low-speed type (Lead: 2.5 mm) Current-limiting value (%) Push force (N) Medium-speed type (Lead: 5 mm) Current-limiting value (%) High-speed type Push force (N) (Lead: 10 mm) Current-limiting value (%) Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution.
6.2 Explanation of Modes Positioning Mode Push = 0 Position complete signal Completed position number Speed 6.2.1 Output (1) The position complete output will turn ON at a position preceding the target position by the positioning band. A completed position number signal will be output at the same time. Moving distance Positioning band 6.2.
Load was not contacted (missed) Speed (2) Completed position number Output Moving distance Positioning band (3) (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 current-limiting 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 Positioning Positioning band band 6.2.3 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.
6.2.5 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.
6.2.6 Zone Signal Output A signal will be output when the actuator enters the specified zone. The zone signal will turn ON when the actuator enters the zone predefined by the applicable parameters. (The zone can be set arbitrarily.) Zone signal Actuator operation Zone signal setting range If parameter No. 25 is set to “3: [2 zone output signals],” two zone output signals can be set. The second zone value is set by parameter No. 23 (Zone 2+) and No. 24 (Zone 2-).
6.2.8 Teaching Mode (Jogging/Teaching Using PIO) The actuator can be jogged using PIO if parameter No. 25 (PIO pattern) is set to “4: [Teaching].” The current actuator position can also be read into the controller’s position-data table using PIO. Switching between the normal positioning mode (including the push & hold mode) and the teaching mode is implemented by turning ON/OFF the operation mode input.
6.2.9 Overview of the “4 Points” (Air Cylinder) Mode This mode provides a control method adjusted to that of an air cylinder by assuming that the RCP2 is used as an air cylinder. The key differences between the RCP2 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.
6.3 Notes on the ROBO Gripper (1) Finger operation [1] Definition of position With the two-finger type, the stroke in the specification represents the sum of travels of both fingers. Therefore, the travel of one finger is one-half the stroke. The position is specified as a travel of one finger from the home toward the closing side. Accordingly, the maximum command value is 5 mm for the GRS type and 7 mm for the GRM type. [2] Definition of speed and acceleration The command value applies to each finger.
(2) Removing the gripped load This gripper is designed to maintain the load-gripping force via a self-lock mechanism even when the servo is turned OFF or the controller power is cut off. If the gripped load must be removed while the power is cut off, do so by turning the open/close screw or removing the finger attachment on one side. [Two-finger type] Turn the open/close screw or remove the finger attachment on one side.
7. Operation 7.1 How to Start 7.1.1 Standard Specification (1) Connect the motor cable and encoder cable to the controller. (2) Connect the host PLC to the PIO connector using the supplied flat cable. (3) If two or more axes are connected, set the necessary items using the address switch. For details, refer to 9, “Controlling Multiple Controllers via Serial Communication.” (4) Actuate an emergency stop or cut off the motor power. (5) Supply 24 VDC to the controller’s terminal block.
Overview of operation on the PC software Select an applicable position data in the main window, and then click the [Home] button. For details, refer to the operation manual for the teaching pendant or PC software. Issuing a command from the PLC Perform signal processing appropriate for the selected PIO pattern by referring to 7.2.1, “Standard Specification.” Issue a command after confirming that the position complete signal (PEND) has turned ON.
7.1.2 Absolute Specification (Absolute Reset) (1) Connect the motor cable and encoder cable to the controller. (2) Connect the host PLC to the PIO connector using the supplied flat cable. (3) If two or more axes are connected, set the address of each axis using the address switch. For details, refer to 9, “Controlling Multiple Controllers via Serial Communication.” (4) Actuate an emergency stop or cut off the motor drive power. (5) Connect the battery connector.
(10) Cancel the emergency stop or supply the motor drive power. The ALM lamp will turn off. (11) Input a servo ON signal (SON) from the PLC (if these signals are enabled). The controller servo will turn ON and the RUN lamp (LED) will illuminate. The position complete output (PEND) and ready output (SRDY) will also turn ON. If the ALM lamp is lit, there is an error. Refer to the alarm table and take an appropriate action. (12) Perform home return.
Timing chart at startup Safety circuit condition Emergency stop is actuated or motor drive power is cut off 24-VDC power ON Initial parameter settings Resetting the alarm • RCA-T/E: Press the BEGIN/END key. • RCB-J: Press the STOP key. • PC software: Click the [Alarm] button. • PLC command: Start signal (CSTR)/reset signal (RES) Emergency stop is not actuated or motor drive power is supplied * Keep the power supplied for at least 48 hours to charge the battery.
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 Standard Specification When the PIO pattern is “0: [Conventional]” Select and input a desired command position number in which a target position is registered, and then input the start signal. Home return is executed first, and then the actuator moves to the target position.
7.2.2 Absolute Specification Home return must be executed when the controller is started for the first time. Even after the home has been established, home return will become necessary if the current position is lost due to low battery voltage, etc. If the home return completion (HEND) is OFF when the power is input, check the cause and then reset the alarm to turn the alarm output (*ALM) ON. Next, be sure to execute home return and confirm that the home return completion (HEND) will turn ON.
7.2.3 Operation Timings at PIO Pattern = “0: [Conventional]” (Example) 100 mm is set as the target position under position No. 3, and home position has not been established yet [Operation with the standard controller] Command position PC1 PC2 Start CSTR Position complete PEND Home return completion HEND Completed position PM1 PM2 Actuator movement Mechanical end Home position Stops after moving to the 100-mm position.
7.2.4 Operation Timings at PIO Pattern = “5: [4 Points]” (Example) When “30 mm” is set as the target position in position No. 0 (Rear end), and the home position is not yet established. [Operation with the standard controller] Rear end move ST0 Position complete REND Home return completion HEND Rear end complete PE0 Actuator movement Mechanical end Home position Stops after moving to the 30-mm position.
7.2.5 Operation Timings at PIO Pattern ≠ “0: [Conventional]” or “5: [4 Points]” Home return HOME Position complete PEND Moving MOVE Home return completion HEND Actuator movement Mechanical end Stops at the home position. Note: When the home return signal turns ON, the position complete output will turn OFF and the moving output will turn ON. The home return signal must be turned OFF with the confirmation that the home return completion signal has turned ON while the home return signal remains ON.
7.3 Home Return and Movement after Start (PIO Pattern = “1: [Standard]”) First, force the position complete signal to turn ON 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.
Command position Position 1 T1 Start Note Position complete Position 1 Completed position Home return completion Moving 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. (The position complete output will not turn ON if the servo ON input is OFF.) To check if the controller is ready, always check if the position complete output is 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. RCP2 controller PIO Signal name Reference flow Category [13] [10] [5] [2] Start [1] [1] Select/enter command position 1.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 1 2 * 250 100 * 200 100 Acceleration/ deceleration * 0.3 0.3 Push Positioning band * 0 0 * 0.1 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 1 2 * 280 40 * 200 100 Acceleration/ deceleration * 0.3 0.3 Push Positioning band * 50 0 * 15 0.
7.6 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. Position Speed 0 1 2 * 150 200 * 200 100 Acceleration/ deceleration * 0.3 0.3 Push Positioning band * 0 0 * 10 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 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. Entering “0.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 1 * 150 * 200 Acceleration/ deceleration * 0.1 Push Positioning band * 0 * 0.1 Acceleration only MAX * 1 Command position Position 1 T1 Start Position complete Position 1 Completed position Moving 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. RCP2 controller PIO Signal name [5] [2] Reference flow Category Select/enter a desired command position. [2] Start input ON Start Command position 1 [1] [1] Command position 2 Command position 4 Movement to the selected position starts.
Command position Start Note Position complete Completed position Pause Moving 4 msec or less 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 and the moving output will turn ON.
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 Parameter No. 2 Zone boundary+ Zone boundary– 120 40 If parameter No.
Command position T1 Note Start Position complete Completed position Zone Moving 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 and the moving output will turn ON.
.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. RCP2 controller PIO Signal name [13] [10] [5] [2] [1] [9] Reference flow Category [1] Select/enter command position 1.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 1 2 * 30 10 * 100 20 = Acceleration/ deceleration * 0.3 0.3 Position 1 Command position T1 Push Positioning band * 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. Command position Position 1 Position 2 No.
7.12 Jogging/Teaching Using PIO First, cause the position complete signal to turn ON by referring to 7.1, “How to Start.” If parameter No. 25 (PIO pattern) is set to “4: [Teaching],” the actuator can be jogged using PIO. The current actuator position can also be read into the controller’s position table using PIO. When reading the current position into the position table, all data other than position (speed, acceleration, etc.
Jogging/teaching timing Operation mode (MODE) Current operation mode (MODES) +Jog (*Pause) -Jog (Reset) Command position Position 1 Current-position write (Start) Write completion (Position complete) (PWRT) T1 (WEND) T1: 20 msec or more; time after the current-position write input is turned ON until writing of the current position is started When the operation mode (MODE) input is turned ON, the current operation mode (MODES) output will turn ON to activate the teaching mode where jogging and tea
7.13 Operation in the “4 Points (Air Cylinder)” Mode First, refer to 7.1, “How to Start,” to turn ON the position complete signal. Example of 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 intermediate point 1 (200 mm) (based on the standard specification).
Rear end move Intermediate point 1 move Front end move Position complete Home return completion Rear end complete Intermediate point 1 complete Front end complete Speed Front end Intermediate point 1 Rear end Home position Mechanical end Actuator movement 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 ST3) 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.
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 parameters for home return offset, soft limits and direction of excitation phase signal detection, if necessary. Note: The home direction cannot be reversed for a rod-type actuator.
Default positioning band (in-position) The factory setting is “0.10 [mm].” When a target position is written to an unregistered position table or the current position is read in the teaching mode, the setting in this parameter will be used as the positioning band data for the applicable position number. Increasing the default positioning band will allow the position complete signal to be output early. Change the setting in parameter No. 10, as necessary.
Current-limiting value at standstill during positioning The factory setting conforms to the standard specification of the actuator. Increasing this setting will increase the holding torque at standstill. This setting need not be changed in normal conditions of use. However, to prevent hunting caused by large external force applied while the actuator is at standstill, the value set in parameter No. 12 must be increased. (Do not increase the value beyond 70%.
8.3.3 Parameters Relating to the External Interface PIO pattern selection Select the PIO operation pattern in parameter No. 25. This setting forms the basis of operation, so be sure to set this parameter at the beginning. The factory setting is “0: [Conventional].” Parameter No. 25 setting 0 1 2 3 4 5 114 Feature of PIO pattern Conventional This pattern is compatible with the pin assignments of the RCP controller.
Movement command type When the PIO pattern is set to “4 points,” define the operation condition of the movement command input (ST0 to ST3) 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.
Pause input disable selection Parameter No. 15 defines whether the pause input signal is disabled or enabled. Enable (use) the signal Disable (do not use) the signal Setting 0 1 The factory setting is “0: [Enable].” Servo ON input disable selection Parameter No. 21 defines whether the servo ON input signal is disabled or enabled. Enable (use) the signal Disable (do not use) the signal Setting 0 1 The factory setting is “1: [Disable].
9. Controlling Multiple Controllers via Serial Communication This section explains the connection method to be used when multiple controllers are controlled using the PC or PLC’s communication module as the host. 9.1 Basic Specifications Specification item Maximum number of units that can be connected Maximum cable length Terminal resistor Description 16 units 100 m or less 220 Provide a communication path via bus connection and be sure to provide a terminal resistor at the end. 9.
9.3 SIO Converter This is a converter unit conforming to RS485/232C. [2] Link-connection terminal block (TB1) TB1 A [6] Monitor LEDs LED1 0V FG 24V EMG1 EMG2 [1] Power/emergency-stop terminal block (TB2) TB2 B ON LED2 RS232 PORT [3] D-sub, 9-pin connector [5] PORT switch [4] Mini DIN, 8-pin connector [1] Power/emergency-stop terminal block (TB2) EMG1, EMG2 24V 0V FG Provide a contact output for the emergency-stop switch on the teaching pendant.
[2] Link-connection terminal block (TB1) A connection port for linking the controller. “A” on the left side connects to pin 1 (SGA) in the controller’s communication connector. “B” on the right side connects to pin 2 (SGB) in the controller’s communication connector. (Note) Be sure to use twisted pair wires for the above two connections (SGA/SGB). [3] D-sub, 9-pin connector A connection port with the host PC or PLC’s communication module.
9.4 Address Switch Set an address (0 to 15) as a hexadecimal (0 to F) using the ADRS switch on the front panel of each controller to define the slave number for the controller. Assign “0” to the controller nearest the host, and then assign 1, 2, 3, …, E and F to the remaining controllers in the direction of moving away from the host. After all addresses have been set, reconnect the power. Note: After the setting, be sure to confirm that the addresses are not duplicated.
9.
10. Troubleshooting 10.1 Action to Be Taken upon Occurrence of Problem Upon occurrence of a problem, take an 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. RDY (green) --- Power is supplied and the CPU is operating properly. RUN (green) --- The servo is ON. ALM (red) --An alarm is present, or an emergency stop has been actuated or the motor drive power is cut off.
10.2 Alarm Level Classification Alarms are classified into three levels according to the symptoms they represent. Alarm level ALM lamp Unlit Message (Note 1) *ALM signal What happens when alarm generates How to reset Not output An error is displayed on the PC or teaching pendant. Input the reset signal from the PLC (Note 2). Reset by the PC/teaching pendant. Reconnect the power. Operation cancellation Lit Output The actuator decelerates to a stop and then the servo turns OFF.
10.3 Alarm Description Output Using PIO So that the PLC can recognize the nature of each alarm that has generated, alarm description is output using the ports for completed position output signals (PM1 to PM8). Configure the system in such a way that the PLC can determine whether the output is a completed position number or alarm description based on the ON/OFF status of the alarm output signal (*ALM).
10.
Code Error name Cause/Action 76 Soft reset during servo ON Cause: A soft reset command was sent while the servo was ON during an operation by serial communication. (PIO commands are excluded.) Action: Send a soft reset command after confirming that the servo is OFF. Cause: A position movement command was entered from a PC or teaching pendant while the teaching mode was selected. (Only the JOG inputs are enabled in the teaching mode.
Code Error name Cause/Action C0 Excessive actual speed C1 Servo error C9 Excessive motor supply voltage CA Overheating CC Overvoltage of control power supply Cause: This alarm indicates that the motor speed exceeded the maximum speed set in the applicable system parameter.
Code Error name Cause/Action CE Drop in control supply voltage This alarm indicates that the voltage of the 24-V input power supply has dropped (24V – 20%: 19.2V or less). Cause: [1] Low voltage of the 24-V input power supply [2] Faulty part inside the controller Action: Check the voltage of the input power supply. If the voltage is normal, please contact IAI. Cause: [1] The battery voltage was 4.4 V or below when the power was input.
(3) Cold-start level alarms Code B8 D8 E8 E9 EA Error name Cause/Action Pole sense error This controller will conduct excitation phase detection when the servo is first turned ON after the power was input. This alarm indicates that the specified encoder signal level cannot be detected after 100 ms of excitation. Cause: [1] Loose or disconnected motor-extension cable connector [2] Brake cannot be released on a controller equipped with brake.
Code Error name F8 Damaged nonvolatile memory FA CPU error FB FPGA error 130 Cause/Action Abnormal data was detected during the nonvolatile memory check after starting. Cause: [1] Faulty nonvolatile memory [2] The memory has been rewritten more than 100,000 times. (The nominal rewrite limit of the nonvolatile memory is around 100,000 times.) Action: If the alarm generates again after reconnecting the power, please contact IAI. The CPU is not operating properly.
10.5 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 112 113 114 115 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. Value too small The entered value is smaller than the setting range.
Code Error name Cause/Action 20C CSTR-ON during operation 20D STP-OFF during operation 20E Soft limit over 20F Push & hold missed-contact This message indicates that the actuator didn’t contact the load during push & detection hold operation. Check the load condition and review the target position/positioning band settings.
10.6 Specific Problems 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 will 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 current. [3] Contact failure in the connector or relay terminal block on the PLC end.
Home return ends in the middle in a vertical application. Cause: [1] The load exceeds the rating. [2] The ball screw is receiving torsional stress due to the affixing method of the actuator, tightening of bolts only on one side, etc. [3] The slide resistance of the actuator itself is large. Action: [1] Increase the value set in parameter No. 13 (Current-limiting value during home return). Increasing this value increases the home return torque.
The actuator moves only a half of, or twice as much as, the specified movement. Cause: [1] The combination of controller and actuator is wrong. The lead length of the ball screw varies depending on the actuator type, so a wrong combination will cause the movement and speed to change. [2] Factory setting error at IAI Action: [1] If multiple actuators of different types must be used, confirm using the identification labels, etc., that the correct actuator is connected to the controller.
Abnormal operation results when the servo is turned ON after the power ON. Cause: Excitation phase detection was not performed correctly when the servo was turned ON, because one of the following conditions existed when the power was input: [1] The slider or rod was contacting the mechanical end. [2] The load was being pushed by a strong external force. Action: [1] Check if the slider or rod is contacting the mechanical end.
11. Function Check and Replacement of the Radiating Fan The large-capacity type (RCP2-CF-***) has a built-in radiating fan. To check the function of this fan and replace the fan when found faulty, follow the steps explained below. 1) Disconnect all connectors and cables from the controller, and then remove the fan unit. Remove everything except for the MPI/MPO jumper wires. 2) Remove the resin case. The hooks on the mounting base plate are secured in the notches provided in the resin case.
3) Check if the fan is normal. Check method: [1] [2] Connect the power cable to the 24V and N terminals on the power terminal block. Turn on the power to see if the fan operates. If the fan is normal, it will operate for approx. 3 seconds. If the fan is faulty, it will not operate. (Note) To prolong the life of the fan, the surrounding air temperature of the power transistor is detected using a temperature sensor. The fan will start when the detected temperature rises to 60°C or above.
12. Replacing the Absolute Data Retention Battery Follow the procedure below when replacing the absolute data retention battery in your controller of absolute specification. [Replacement Part] Absolute data retention battery AB-4 [Replacement Procedure] 1) Unplug the cable from the battery connector. 2) Remove the cover screws.
3) Take out the cover and replace the battery with a new one. 4) Tighten the cover screws. 5) Plug the cable into the battery connector. 6) Perform an absolute reset in the steps below. Perform an absolute reset by issuing a command from the teaching pendant, in the PC software or from the PLC. [1] Reset the alarm (clear the error message) and return the *ALM signal to the ON state. [2] Perform a home return operation.
Appendix * Appendix List of Supported Actuator Specifications Slider, ball-screw drive type Stroke (mm) and maximum speed (mm/sec) (Note 1) Vertical Rated acceleration Horizontal Vertical Water- High proof speed Motor reversed Motor straight Model number Load capacity (Note 2) Horizontal (Note 1) The figure in the elongated circle indicates the maximum speed for the applicable strokes. The maximum speeds in vertical applications are shown in ( ).
Appendix Rod type Stroke (mm) and maximum speed (mm/sec) (Note 1) Load capacity (Note 2) Horizontal Rated acceleration Vertical Horizontal Vertical High thrust Double guides Single guide Splash-proof Standard Model number (Note 1) The figure in the elongated circle indicates the maximum speed for the applicable strokes. The maximum speeds in vertical applications are shown in ( ). (Note 2) The load capacity is based on operation at the rated acceleration.
Appendix Correlation diagrams of speed and load capacity of the slider, motor-straight 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) (Note) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) In the above graphs, the figure after each model type indicates a lead.
Appendix Correlation diagrams of speed and load capacity of the slider, motor-reversed 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) (Note) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) In the above graphs, the figure after each model type indicates a lead.
Appendix Correlation diagrams of speed and load capacity of the slider, high-speed ball-screw type Vertical installation Load capacity (kg) Load capacity (kg) Horizontal installation Speed (mm/sec) (Note) Speed (mm/sec) The load capacity varies depending on the acceleration. Vertical installation Load capacity (kg) Load capacity (kg) Horizontal installation Speed (mm/sec) (Note) Speed (mm/sec) The load capacity varies depending on the acceleration.
Appendix Correlation diagrams of speed and load capacity of the rod, standard type Vertical installation Load capacity (kg) Load capacity (kg) High-speed type Horizontal installation (Note 1) 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 figure after each model type indicates a lead.
Appendix Correlation diagrams of speed and load capacity of the single-guide 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) (Note) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) In the above graphs, the figure after each model type indicates a lead.
Appendix Correlation diagrams of speed and load capacity of the double-guide 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) (Note) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Low-speed type Speed (mm/sec) Speed (mm/sec) In the above graphs, the figure after each model type indicates a lead.
Appendix Correlation diagrams of speed and load capacity of the dust-proof/splash-proof type Vertical installation (Note 2) Load capacity (kg) Load capacity (kg) High-speed type Horizontal installation (Note 1) 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 figure after each model type indicates a lead.
Appendix Correlation diagrams of speed and load capacity of the high-thrust 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) Correlation diagram of speed and load capacity of the waterproof type Load capacity (kg) Lead: 4 Lead: 8 S
Appendix Example of Basic RCP2 Positioning Sequence Given below is an example of basic sequence for creating a positioning sequence using the RCP2. indicates PIO signals of the RCP2 controller.
Appendix (Positioning circuit for position 2) Positioning start request to position 2 M N 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 Current positioning completed position (A) M P O O PEND Q P P B Q Auxiliary start signal for next positioning
Appendix R PC1 Command position 1 PC2 Command position 2 PC4 Command position 4 PC8 Command position 8 Position 3 set signal Position 5 set signal S Position 3 set signal Position 6 set signal (Start signal circuit) J Timer 2 O 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 Valid only when [64-point positioning] is selected No.
Appendix Recording of Parameters 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.
Change History Revision Date Description of Revision First edition December 2005 February 2006 Tenth edition Eleventh edition April 2007 Twelfth edition April 2009 Thirteenth edition • Corrected the clerical error in the description of average life of the battery specification, from 4 years to 3 years. February 2010 June 2010 April 2011 Fourteenth edition • Added that the pollution degree 2 is supported in the applicable UL standard field. • Added the item about CE Marking.
Manual No.: ME0136-16A (April 2011) 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.
