IAI RA3R Operating Manual Download Page 1

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IAI America, Inc.

ROBO Cylinder

Third Edition

Motor Straight Type (Coupling Type): RA3C, RGS3C, RGD3C, RA4C, RGS4C and RGD4C
Motor Straight Type (Built-in Type):

RA3D, RGS3D, RGD3D, RA4D, RGS4D and RGD4D

Motor Reversing Type:

RA3R, RGS3R, RGD3R, RA4R, RGS4R and RGD4R

Rod Type

RCA Actuators

Motor Straight Type (Coupling Type): RA3C and RA4C
Motor Straight Type (Built-in Type):

RA3D and RA4D

Motor Reversing Type:

RA3R and RA4R

RCAW Actuators, Dustproof/Splash-proof Type

Operating Manual

Summary of Contents for RA3R

Page 1: ...t Type Built in Type RA3D RGS3D RGD3D RA4D RGS4D and RGD4D Motor Reversing Type RA3R RGS3R RGD3R RA4R RGS4R and RGD4R Rod Type RCA Actuators Motor Straight Type Coupling Type RA3C and RA4C Motor Straight Type Built in Type RA3D and RA4D Motor Reversing Type RA3R and RA4R RCAW Actuators Dustproof Splash proof Type Operating Manual ...

Page 2: ...ugh failure to do so will not result in injury It should be noted that the instructions under the Caution and Note headings may also lead to serious consequences if unheeded depending on the situation All instructions contained herein provide vital information for ensuring safety Please read the contents carefully and handle the product with due caution Please keep this operating manual in a conve...

Page 3: ...check the operation area of the equipment to ensure safety Supplying power to the product carelessly may cause electric shock or injury due to contact with the moving parts z Wire the product correctly by referring to the operation manual Securely connect the cables and connectors so that they will not be disconnected or come loose Failure to do so may cause the product to malfunction or cause fir...

Page 4: ...res if the product is used in any of the following places If proper measures are not taken the product may malfunction 1 Place where large current or strong magnetic field generates 2 Place where arc discharge occurs due to welding work etc 3 Place where noise generates due to electrostatic etc 4 Place where the product may come in contact with radiation z Do not install the product in a place sub...

Page 5: ...l circuit that will cause the work to drop in case of power failure Configure a control circuit that will prevent the table or work from dropping when the power to the machine is cut off or an emergency stop is actuated z The following conditions must be met in order to improve the straightness of the table movement and ensure the smooth movement of the ball screw and linear guides 1 Flatness of t...

Page 6: ...d the information carefully to connect the cables properly 1 Do not let the cable flex at a single point 2 Do not let the cable bend kink or twist 3 Do not pull the cable with a strong force 4 Do not let the cable receive a turning force at a single point 6 Do not pinch drop a heavy object onto or cut the cable 5 When fixing the cable provide a moderate slack and do not tension it too tight Steel ...

Page 7: ...he cable will not become too taut when bent z Do not cause the cables to occupy more than 60 of the space in the cable bearer z Do not lay signal lines together with circuit lines that create a strong electric field z The supplied cables are not robot cables Accordingly never store the cables in a cable bearer z Always use a robot cable for each relay cable Bending radius r z Use a cable bearer wi...

Page 8: ...5 2 Handling the Actuator Assembly 10 5 2 1 Condition of Shipment from IAI Assembled 10 5 2 2 Handling after Assembly with Peripheral Equipment 10 6 Operating and Storage Environment 11 6 1 Operating Environment 11 6 2 Storage Environment 11 7 Installation 12 7 1 Installing the Main Body 12 8 Wiring Cable 22 9 Connecting the Air Tube of the RCAW Dustproof Splash proof Type 23 10 Maximum Speed 24 1...

Page 9: ...sing Type RA3R RA4R Types 32 14 6 Replacing the Motor 37 14 6 1 Replacing the Motor of the Motor Straight Type Coupling Type RA3C RA4C Types 37 14 6 2 Replacing the Motor of the Motor Reversing Type RA3R RA4R Types 44 14 7 Replacing the Bellows of the RCAW Dustproof Splash proof Type 50 15 Cable Drawings 53 ...

Page 10: ......

Page 11: ... the unit when it is in operation or when the power is ON since this is dangerous 2 2 Maintenance and Inspection When doing maintenance and inspection work always shut down the controller power first When doing inspection make sure that no one can inadvertently turn the power ON Make sure that a sign indicating work in progress is clearly visible If several persons are working be sure to watch out...

Page 12: ...t wear out with use stainless sheet etc Unit seems to be noisy or similar impressions that do not affect machinery performance Damage resulting from improper handling by the user or lack of proper maintenance Any alterations made by other than IAI or its representatives Breakdowns caused by using controllers made by other manufacturers Any damages caused by fire and other natural disasters or acci...

Page 13: ...aight Type Coupling Type No Guide z RCA RA3C RCA RA4C Caution The cable directly connected to the actuator is not robot cable even when ordered with robot cable option When designing please be sure not to give repeated bending loads to this cable The robot cable is applicable only to the connecting cables Rod side Motor side Right Left Rod Rod cover Cylinder tube Head cover Motor unit Cable Rod ti...

Page 14: ...o the actuator is not robot cable even when ordered with robot cable option When designing please be sure not to give repeated bending loads to this cable The robot cable is applicable only to the connecting cables Rod side Motor side Right Left Rod Rod cover Cylinder tube Head cover Motor unit Cable Rod tip adapter ...

Page 15: ... not robot cable even when ordered with robot cable option When designing please be sure not to give repeated bending loads to this cable The robot cable is applicable only to the connecting cables Rod side Motor side Right Left Rod Rod cover Cylinder tube Head cover Motor unit Cable Rod tip adapter Pulley case ...

Page 16: ... actuator is not robot cable even when ordered with robot cable option When designing please be sure not to give repeated bending loads to this cable The robot cable is applicable only to the connecting cables Rod side Motor side Right Left Rod Rod cover Cylinder tube Head cover Motor unit Cable Guide bracket Guide bearing Guide rod ...

Page 17: ... actuator is not robot cable even when ordered with robot cable option When designing please be sure not to give repeated bending loads to this cable The robot cable is applicable only to the connecting cables Rod side Motor side Rod Rod cover Cylinder tube Head cover Motor unit Cable Guide bracket Guide bearing Guide rod Right Left ...

Page 18: ...ctuator is not robot cable even when ordered with robot cable option When designing please be sure not to give repeated bending loads to this cable The robot cable is applicable only to the connecting cables Rod side Motor side Right Left Rod Rod cover Cylinder tube Head cover Motor unit Cable Bellows Intake exhaust port Rod tip adapter ...

Page 19: ...osition Do not climb on top of the shipping box Do not place heavy objects on top of the shipping box 5 1 2 Handling the Actuator After It is Unpacked Lift the actuator up by the base to remove it from the packing When transporting the actuator be careful not to hit it against nearby structures or object In particular exercise caution to protect the motor unit and pulley case against impact Do not...

Page 20: ... as not to apply impact to the assembly or cause it to bounce After unpacking handle the actuator assembly correctly by observing the instructions given below 5 2 2 Handling after Assembly with Peripheral Equipment When transporting the actuators that have been assembled with peripheral equipment either at IAI or on your site observe the instructions given below Secure the rod so that it will not ...

Page 21: ...hich an operator can work without protective gear RCA Work space needed for maintenance inspection Motor straight type Motor reversing type If you are using the dustproof splash proof type RCAW type consult IAI beforehand This product is not designed by considering chemical resistance Contact IAI for splash proof resistance to liquids other than water 6 2 Storage Environment The storage environmen...

Page 22: ...tuator using screws set on the rod or head side of the actuator z Applicable models All models Type MA MB RA3 type M26 x 1 5 M35 x 1 5 RA4 type M30 x 1 5 M40 x 1 5 Straight type Rod cover Cylinder tube Head cover Motor unit Reversing type MA MB Pulley case Rod Rod cover MA Cylinder tube Head cover MA ...

Page 23: ...alling the actuator Use this flange if necessary z Applicable models All models Mating material is steel Mating material is aluminum Screw size M6 M6 Tightening torque 12 3 N m 5 4 N m Straight type Mounting hole Affixing nut Flange Straight type Mounting hole Affixing nut Flange ...

Page 24: ... Mating material is steel Mating material is aluminum Screw size M6 M6 Tightening torque 12 3 N m 5 4 N m Reversing type Mounting hole Affixing nut Flange Mounting hole Affixing nut Flange Reversing type ...

Page 25: ...M6 M6 Tightening torque 12 3 N m 5 4 N m Caution Affix the actuator using two feet optional one in the front and the other in the back If affixed using only one foot in the front or back the actuator may be negatively affected due to insufficient rigidity Straight type Mounting hole Affixing nut Foot A Affixing nut Affixing nut Mounting hole Foot B Reversing type Mounting hole Mounting hole Affixi...

Page 26: ...runnion if necessary z Applicable models RA3C RA3D RA4C RA4D Mating material is steel Mating material is aluminum Screw size M6 M6 Tightening torque 12 3 N m 5 4 N m Straight type Mounting hole Affixing nut Trunnion ring Straight type Mounting hole Affixing nut Bracket B Bracket A Trunnion ring Bracket A Bracket B ...

Page 27: ...nstalled horizontally using any of the aforementioned means add a guide or other appropriate mechanism to prevent the rod from receiving the actuator weight Caution The optional clevis and trunnion are designed so that the fulcrum shaft can only receive radial load In a condition where play is not permitted or thrust load is received the customer must design a separate bearing structure Caution Th...

Page 28: ...ult the bush may wear quickly or internal mechanical parts may be damaged If the actuator is installed horizontally using any of the aforementioned means add a guide or other appropriate mechanism to prevent the rod from receiving the actuator weight Caution The optional clevis and trunnion are designed so that the fulcrum shaft can only receive radial load In a condition where play is not permitt...

Page 29: ...t is available for installing the actuator Use this rear mounting bracket if necessary z Applicable models Motor reversing type RCA RA3R RCA RA4R Type Tapped hole diameter Tapped depth Tightening torque RA3 type M4 6 mm 1 8 N m RA4 type M4 7 mm 1 8 N m Reversing type Tapped mounting hole ...

Page 30: ...racket for installing an actuator of the double guide type z Applicable models Double guide type RGD3 RGD4 Type Tapped hole diameter Tapped depth Tightening torque RA3 type M5 8 mm 3 4 N m RA4 type M5 8 mm 3 4 N m Tapped mounting hole Bracket A Bracket B ...

Page 31: ...racket for installing an actuator of the single guide type z Applicable models Double guide type RGD3 RGD4 Type Tapped hole diameter Tapped depth Tightening torque RA3 type M5 8 mm 3 4 N m RA4 type M5 8 mm 3 4 N m Tapped mounting hole Bracket A Bracket B ...

Page 32: ...it the load on the cable Never cut and or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length The cables supplied with the actuator offer excellent flexibility but they are not robot cables If the cables are to be stored in a movable cable duct cable bearer etc use robot cables For cable modification please contact your IAI sales representativ...

Page 33: ... 5 mm on the intake exhaust port and guide the air tube to a location where the external environment assures the tube will not come in contact with water Applicable tube Shown below is a representative model of air tube that can be installed on the RCAW TU1065 Polyurethane tube Manufacturer SMC Caution The air tube should not be more than 3 m long ...

Page 34: ... If the maximum speed limit is exceeded noise may increase or vibration may occur due to resonance of the ball screw shaft in which case the service life of the actuator may be significantly reduced If multiple actuators are used together with each actuator operating independently create programs where each actuator does not exceed the applicable maximum speed see the table above If operations of ...

Page 35: ... the actuator in the moving direction of the load Do not allow the rod slide shaft to receive rotational torque Doing so may damage the internal parts Tighten the nut at the tip of the rod while securely holding the rod using a wrench of size 17 RA4 or 13 RA3 12 Actuators with a Switch Optional On actuators with a switch the switch is stored inside the actuator body on the motor side Do not increa...

Page 36: ...he actuator has a rated acceleration deceleration of 0 3 G and is combined with a controller of power saving specification with lower peak current Blank Conventional specification The actuator has a rated acceleration deceleration of 0 3 G and is combined with a conventional controller Example RCA RA3C I 20 10 50 A1 S HA High acceleration deceleration type RCA RA4C I 20 10 50 A1 S LA Power saving ...

Page 37: ... 2 Power saving specification ACON C 20ILA NP 2 0 3 Conventional specification ACON C 20I NP 2 0 Standard specification high acceleration deceleration option Power saving option Actuator Rated Maximum 2 Rated Maximum 2 RA3C RGS3C RGD3C 1 7 A 5 1 A 1 7 A 3 4 A RA4C RGS4C Load current 1 RGD4C 1 3 A 4 0 A 1 3 A 2 2 A 1 When the power is turned on rush current corresponding to around 5 to 12 times the...

Page 38: ...reafter 1 Apply grease to the sliding surface of the rod at the startup check if grease has been consumed or every three months For the RCAW dustproof splash proof type apply grease when the bellows is changed 14 2 Visual Inspection of the Machine Exterior Check the following items visually Body Loose mounting bolts Cables Damage to cables or connection to connector box General Unusual noise or vi...

Page 39: ...plicable grease Kyodo Yushi Multemp LRL3 Warning Never use any fluorine based grease It will cause a chemical reaction when mixed with a lithium based grease and may cause damage to the actuator 2 How to apply grease Apply grease over the entire surface of the rod ...

Page 40: ... to withstand several millions of flexing loads As a practical guideline replace the reduction belt when any of the conditions listed below is observed The teeth and end faces of the belt have worn significantly The belt has swollen due to deposits of oil etc Cracks and other damages are found on the teeth or back of the belt The belt has broken 14 5 2 Applicable Belt RA3R 60S2M124R Rubber cleanro...

Page 41: ...or unit and pull the string to the specified tension using a tension gauge In this condition uniformly tighten the motor unit affixing bolts Recommended tightening torque of adjustment bolts 162 N cm 16 5 kgf cm Tension 2 5 kgf Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats ...

Page 42: ... mechanical end In this position loosen the motor unit affixing bolts and replace the belt 2 Restore the home position Affix the rod at a position 2 mm from the mechanical end on the home side pass the belt and adjust the belt to the specified tension 3 Perform homing using a PC or teaching pendant and check for deviation from the initial home position If there is a deviation adjust the home offse...

Page 43: ...osition Warning If the actuator is installed vertically move it after turning on the controller power and forcibly releasing the brake At this time beware of danger as the actuator may drop suddenly Always provide a support to brace the actuator hand to prevent sudden drop so as not to pinch fingers or damage the load M3 hexagon socket head screws M4 hexagon socket head screws Cause the rod to pro...

Page 44: ...ust it to achieve proper alignment The ball screw side should be at a position where the rod projects 2 mm from the mechanical end After the check attach a new belt while holding the pulleys on both sides in position Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats Motor side Ball screw side Initial countermar...

Page 45: ...n gauge to the specified tension In this condition uniformly tighten the motor unit affixing bolts Recommended tightening torque for adjustment bolts 162 N cm 16 5 kgf cm Tension 2 5 kgf Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats ...

Page 46: ...ute reset must be performed Check for deviation from the initial home position If there is a deviation adjust parameter No 22 Home offset if you are using an ACON controller If you are using an ASEL controller adjust axis specific parameter No 12 Home preset If your controller is of absolute encoder specification perform homing after changing the parameter and then perform an absolute reset M3 hex...

Page 47: ...n 2 mm from the mechanical end In this position replace the motor 2 Perform homing using a PC or teaching pendant and check for deviation from the initial home position If there is a deviation adjust the home offset if you are using an ACON controller If you are using an ASEL controller adjust the home preset Replacement motor unit Coupling with screws Home position Z phase ON position Mechanical ...

Page 48: ...g the brake At this time beware of danger as the actuator may drop suddenly Always provide a support to brace the actuator hand to prevent sudden drop so as not to pinch fingers or damage the load 2 Using an Allen wench of 2 mm across flats remove the two motor unit affixing bolts on the right and left Cause the rod to project 2 mm from the mechanical end Apply countermarks once the rod has projec...

Page 49: ...a countermark on the cylinder tube at a position corresponding to the tab on the motor unit so that the motor unit and cylinder can be aligned in the correct position later on 4 Apply grease on the actuator coupling Tab on the motor unit Apply a countermark at a position corresponding to the tab on the motor unit ...

Page 50: ...hat of the actuator coupling adjusted to a position corresponding to a rod projection of 2 mm from the mechanical end Apply countermarks to identify the current motor position phase Z position and coupling Align the tab on the replacement motor unit with the countermark on the cylinder Position the couplings Coupling Replacement motor unit After the coupling has been inserted apply countermarks on...

Page 51: ...rench of 2 mm across flats Similarly turn the coupling and motor shaft simultaneously until the other screw is seen through the hole and tighten the setscrew Coupling setscrew hole Turn the coupling and motor shaft simultaneously until a setscrew on the coupling is seen through the hole Thereafter tighten the hexagon socket head setscrew using an Allen wrench of 2 mm across flats ...

Page 52: ...confirm that the orientation of the actuator coupling adjusted to a position corresponding to a rod projection of 2 mm from the mechanical end corresponds to the position of the coupling in the replacement motor unit Apply countermarks on the replacement motor unit and coupling Coupling Replacement motor unit Align the tab on the replacement motor unit with the countermark on the cylinder Confirm ...

Page 53: ... is of absolute encoder specification an absolute reset must be performed Check for deviation from the initial home position If there is a deviation adjust parameter No 22 Home offset if you are using an ACON controller If you are using an ASEL controller adjust axis specific parameter No 12 Home preset If your controller is of absolute encoder specification perform homing after changing the param...

Page 54: ...he rod at a position 2 mm from the mechanical end on the home side pass the belt and adjust the belt to the specified tension 3 Perform homing using a PC or teaching pendant and check for deviation from the initial home position If there is a deviation adjust the home offset if you are using an ACON controller If you are using an ASEL controller adjust the home preset Replacement motor unit Z phas...

Page 55: ...bolts using an Allen wrench of 2 5 mm across flats Slide the motor and loosen and remove the belt After the belt has been removed remove the motor unit affixing bolts Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats Motor unit affixing bolts Use an Allen wrench of 2 5 mm across flats M3 hexagon socket head screws M4 hexagon socket head screws ...

Page 56: ...46 Replacement motor 3 Take out the motor 4 Install the replacement motor Loosely tighten the motor unit affixing bolts ...

Page 57: ...or may drop suddenly Always provide a support to brace the actuator hand to prevent sudden drop so as not to pinch fingers or damage the load 6 Check the following points before restoring the home position The motor side should be aligned with the initial countermark If the position is offset adjust it to achieve proper alignment The ball screw side should be at a position where the rod projects 2...

Page 58: ...llen wrench of 2 5 mm across flats 7 Adjust the belt tension Pass a looped strong string or long tie band around the motor cover and pull it with a tension gauge to the specified tension In this condition uniformly tighten the motor unit affixing bolts Recommended tightening torque for adjustment bolts 162 N cm 16 5 kgf cm ...

Page 59: ...ute reset must be performed Check for deviation from the initial home position If there is a deviation adjust parameter No 22 Home offset if you are using an ACON controller If you are using an ASEL controller adjust axis specific parameter No 12 Home preset If your controller is of absolute encoder specification perform homing after changing the parameter and then perform an absolute reset M3 hex...

Page 60: ... bellows unit RA3 JB RA3 stroke RA4 JB RA4 stroke Phillips screwdriver Torque driver Grease Kyodo Yushi Multemp LRL3 Procedure 1 Loosen the front and rear metal fittings affixing the bellows and remove the bellows Loosening of front metal fitting Loosening of rear metal fitting Removal of bellows Bellows has been removed ...

Page 61: ...51 Bellows Install a metal fitting on the bellows 2 Apply grease evenly over the entire cylinder surface Apply grease evenly over the entire surface 3 Install a metal fitting on the bellows ...

Page 62: ...he replacement new bellows and tighten the screws of the front and rear metal fittings affixing the bellows Tighten the screws to the specified torque using a torque driver Installation of bellows Tightening of rear metal fitting Tightening of front metal fitting ...

Page 63: ...Controller end Actuator end 15 Cable Drawings 1 Motor cable Model CB ACS MA Wire Color Signal No No Signal Color Wire Red U 1 1 U Red White V 2 2 V White AWG22 crimped Black W 3 3 W Black AWG22 crimped 1 3 ...

Page 64: ...nge Green Green Purple Purple Gray Red Black Ground Black Gray Red White blue in the wire color field indicates the band color insulator color Ground LS LS BK BK A A B B SD Z SD Z BAT BAT VCC GND FG No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 No A A B B LS LS FG FG Z Z PS BAT BAT SD SD VCC GND VCC GND LS BK BK LS BK BK 2 Encoder cable robot encoder ...

Page 65: ...MEMO 55 ...

Page 66: ...MEMO 56 ...

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Page 68: ...912 Atlanta Office 1220 E Kenneston Circle Marietta GA 30066 TEL 678 354 9470 FAX 678 354 9471 Website www intelligentactuator com Ober der Röth 4 D 65824 Schwalbach am Taunus Germany TEL 06196 88950 FAX 06196 889524 The information contained in this document is subject to change without notice for the purpose of product improvement Copyright 2008 Apr IAI Corporation All rights reserved ...

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