IAI ROBO Cylinder RCP2 Series Operation Manual Download

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Operation Manual

Fourth Edition

RCP2 Series
Robo Cylinder Controller

Summary of Contents for ROBO Cylinder RCP2 Series

Page 1: ...Operation Manual Fourth Edition RCP2 Series Robo Cylinder Controller ...

Page 2: ...ositioning points However the servo ON input ready output and zone output have been removed 3 2 zone output signals Compared with the standard pattern offering only one zone output signal this pattern provides two zone output signals However the moving output has been removed The boundaries for the second zone output signal are specified in user parameter Nos 23 and 24 4 Teaching This pattern allo...

Page 3: ... power is disconnected However the data may be lost if the nonvolatile memory becomes faulty We strongly recommend that the latest position table and parameter data be backed up so that the data can be restored quickly in the event of power failure or when the controller must be replaced for a given reason The data can be backed up using the following methods 1 Save to a CD or FD from the PC softw...

Page 4: ...se read the operation manuals for all devices including the main unit and controller It is the user s responsibility to verify and determine the compatibility of this product with the user s system and to use them properly After reading the catalog operation manual and other materials be sure to keep them in a convenient place easily accessible to the personnel using this product When transferring...

Page 5: ...blem such as emergency stop or power failure design a safety circuit or other device that will prevent equipment damage or injury z Be sure to provide Class D grounding for the controller and actuator formerly Class 3 grounding Grounding resistance at 100 Ω or less Leakage current may cause electric shock or malfunction z Before supplying power to and operating the product always check the operati...

Page 6: ...sed to dust salt or iron powder in a humid place or in an atmosphere of organic solvent phosphate ester machine oil etc The product may lose its function over a short period of time or exhibit a sudden drop in performance or its service life may be significantly reduced z Do not use the product in an atmosphere of corrosive gases sulfuric acid or hydrochloric acid etc Rust may form and reduce the ...

Page 7: ...nment safety device or other equipment having significant impact on human life or property design operating ranges with sufficient margins from the ratings and design specifications or provide sufficient safety measures such as fail safes Whatever you do always consult IAI s sales representative Installation z Do not place objects around the controller that will block airflows Insufficient ventila...

Page 8: ...is operation manual 4 The information contained in this operation manual is subject to change without notice Q Action to Be Taken in Case of Emergency If this product is found to be in a dangerous condition immediately turn off all power switches of the main unit and connected equipment or immediately disconnect all power cables from the outlets Dangerous condition refers to a situation where the ...

Page 9: ... Noise Elimination 11 3 1 Installation Environment 11 3 2 Power Supply 11 3 3 Noise Elimination and Grounding 11 3 4 Heat Radiation and Installation 13 4 Wiring 14 4 1 Internal Drive Power Cutoff Relay Type 14 4 1 1 Configuration 14 4 1 2 External Connection Diagram 15 4 1 3 Wiring the Power Supply Emergency Stop Switch 16 4 2 External Drive Power Cutoff Relay Type 23 4 2 1 Configuration 23 4 2 2 ...

Page 10: ...5 3 2 Details of Each Output Signal 44 Ready SRDY 44 Moving MOVE 44 Position complete PEND 44 Home return completion HEND 44 Completed position number PM1 to PM32 45 Zone ZONE1 ZONE2 45 Current operation mode MODES 45 Write completion WEND 45 Alarm ALM 46 Emergency stop EMGS 46 Output Signal Changes in Each Mode 47 6 Data Entry Basics 47 6 1 Description of Position Data Table 48 6 1 1 Relationship...

Page 11: ... Incremental Mode 82 7 12 Jogging Teaching Using PIO 84 8 Parameters 86 8 1 Parameter Classification 86 8 2 Parameter Table 86 8 3 Parameter Settings 87 8 3 1 Parameters Relating to the Actuator Stroke Range 87 z Soft limit 87 z Zone boundary 87 z Home return direction 88 z Home return offset 88 8 3 2 Parameters Relating to the Actuator Operating Characteristics 88 z PIO jog speed 88 z Default spe...

Page 12: ...Specific Problems 108 z I O signals cannot be exchanged with the PLC 108 z The RDY lamp does not illuminate after the power is input 108 z Only the RDY lamp illuminates when the servo ON signal is input after the power was input 108 z Both the RDY lamp and ALM lamp illuminate when the power is input 108 z Home return ends in the middle in a vertical application 109 z Noise occurs during downward m...

Page 13: ...ositive and negative terminals to make direct contact Doing so may damage the equipment or cause burns due to the generation of heat 3 Never throw the batteries into a fire because it may cause them to explode Also avoid immersing the batteries in water which can result in loss of battery function 4 Do not solder the batteries directly The safety valve inside the battery cap may be damaged resulti...

Page 14: ...n a place accessible to other people enclose its operating range using a safety cage etc 4 Always turn off the power supply to the controller before assembling adjusting or maintaining inspecting the machine During assembly adjustment or maintenance inspection put a plate or other visible sign in a conspicuous place indicating that work is in progress The operator should keep the entire power cabl...

Page 15: ...wing items are excluded from the scope of warranty Aging such as natural discoloration of coating Wear of a consumable part due to use Noise or other sensory deviation that doesn t affect the mechanical function Defect caused by inappropriate handling or use by the user Defect caused by inappropriate or erroneous maintenance inspection Defect caused by use of a part other than IAI s genuine part D...

Page 16: ...ts Selectable from five patterns LED indicators RDY green RUN green ALM red Communication RS485 1 channel terminated externally Encoder interface Incremental specification conforming to EIA RS 422A 423A Forced release of electromagnetic brake Toggle switch on front panel of enclosure Actuator cable 20 m or less Cable length PIO cable 5 m or less Insulation strength 500 VDC 10 MΩ Environment Operat...

Page 17: ... off for a prolonged period within the specified battery retention time 3 Replacing the batteries Batteries are consumable parts Repeated charging and discharging of the batteries will diminish their initial performance characteristics If the retention time has decreased significantly the batteries may have reached the end of their useful life If this should occur replace the batteries The batteri...

Page 18: ...er label IOPN Write down the PIO pattern selected in user parameter No 25 on this label This will facilitate maintenance if multiple controllers are used in different patterns 4 Teaching pendant PC connector SIO A connector for the dedicated teaching pendant or PC communication cable This cable is also used to link two or more controllers to enable serial communication among them RDY green RUN gre...

Page 19: ... for cutting off the motor drive power MPI and MPO represent the input side and output side of the motor power supply respectively Connect an external safety circuit 24V Positive side of the 24 V power supply N Negative side of the 24 V power supply FG FG of the 24 V power supply 7 I O signal connector PIO A PIO cable connector to the host controller PLC etc 8 Address switch ADRS A switch for sett...

Page 20: ...8 2 3 External Dimensions 2 3 1 Standard Specification RCP2 I An external view and dimensions of the product are shown below 170 5 Mounting dimension 163 178 5 φ 5 68 1 5 35 ...

Page 21: ...9 2 3 2 Absolute Specification with Battery Bracket RCP2 A K Weight 660 g 62 0 2 0 69 7 35 0 178 5 170 5 φ 5 4 8 3 2 5 35 ...

Page 22: ...10 Absolute Specification without Battery Bracket RCP2 A Weight 460 g 35 0 68 1 178 5 170 5 φ 5 3 2 5 35 17 5 67 0 53 0 ...

Page 23: ...controller to direct sunlight or radiating heat from a large heat source such as a heat treatment furnace 4 Use the controller in an environment free from corrosive or inflammable gases under a temperature of 0 to 40 C and humidity of 85 or less non condensing 5 Use the controller in an environment where it will not receive any external vibration or shock 6 Prevent electrical noise from entering t...

Page 24: ... 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 a AC solenoid valves magnet switches and relays Measure Install a surge absorber in parallel with the coil The most effective method is to connect a surge absorber and a surge killer in parallel This way noise will be e...

Page 25: ...ally 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 When installing multiple controllers side by side providing a ventilation fan or fans above the controllers will help maintain a uniform temperature around the co...

Page 26: ... short the S2 and EMG terminals using a jumper wire S1 S2 MPI MPO 24V N EMG PERSONAL COMPUTER Standard teaching pendant RCA T Optional Cable length 5 m External unit RCB 105 2 Cable length 2 m RCB 105 5 Cable length 5 m Optional PC PC software RCB 101 MW Optional External EMG switch Input power supply 24 VDC 24V 0 Host system PLC Supplied flat cable Cable length 2 m Robo cylinder Cable length 5 m ...

Page 27: ...hite Red Black Green GND 24V FG Orange black 2 Orange red 2 Yellow black 1 Yellow red 1 White black 1 White red 1 Light blue black 1 Light blue red 1 Controller Connected to teaching pendant or PC External EMG switch Input power supply 24 VDC 24V 0V FG Host system PLC I O flat cable Refer to 4 3 Connecting the I O Cables for the connection of I O signals PORT switch Terminal block Actuator Motor E...

Page 28: ... sure to install it on the positive side of the 24 V power supply Keep the negative side of the 24 V power supply connected without cutting it off with a relay If a relay is installed on both the positive and negative sides an ABS error may generate b Connect a surge killer to the relay contact Chattering of the relay may have negative effect on the controller Connect a surge killer to prevent mal...

Page 29: ...age Cutoff current EMG switch on teaching pendant 30 VDC 3 A PORT switch 24 VDC 0 1 A Example of recommended circuit Note To cut off the motor drive power supply in conformance with safety category 2 connect 24V to the EMG terminal and a contactor or other contact device to the MPI MPO terminals Refer to 4 2 3 MPO MPI S1 S2 24V N EMG S1 S2 CR ON OFF MPI MPO 24V EMG N CR CR 24V 0V RCP2 PORT switch ...

Page 30: ...s 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 Then provide connections by sequentially connecting the S2 terminal of controller 1 to the S1 terminal of controller 2 the S2 terminal of controller 2 to the S1 terminal of controller 3 and so on and connect the S2 terminal on the last controller to the EMG terminals on all...

Page 31: ... 0V MPO MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 0V MPO MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 0V MPO MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 0V MPO MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 0V ...

Page 32: ...oil current of 0 1 A or less and connect a diode for coil surge absorption C 0V control C 24V P 24V power P 0V CR CR Controller 1 Controller 2 Controller 3 EMG signal MPO MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 N MPO MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 N MPI 24V EMG PORT switch Teaching pendant Relay ON OFF S1 S2 N MPO ...

Page 33: ...xis or axes only CR Controller 1 Controller 2 Controller 3 EMG signal Teaching pendant 24V 0V MPO MPI 24V EMG PORT switch Relay ON OFF S1 S2 N MPO MPI 24V EMG PORT switch Relay ON OFF S1 S2 N Teaching pendant MPO MPI 24V EMG PORT switch Relay ON OFF S1 S2 N Teaching pendant ...

Page 34: ...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 CR EMG signal Teaching pendant 24V 0V PORT switch ON OFF EMG2 EMG1 Controller 1 Controller 2 Controller 3 Relay N MPO MPI 24V EMG Relay N MPO MPI 24V EMG Relay N MPO MPI 24V EMG SIO converter CR ...

Page 35: ...or for motor drive power cutoff circuit Standard teaching pendant RCA T Optional Cable length 5 m External unit RCB 105 2 Cable length 2 m RCB 105 5 Cable length 5 m Optional PC PC software RCB 101 MW Optional Input power supply 24 VDC 24V 0 FG Host system PLC Supplied flat cable Cable length 2 m Robo cylinder Cable length 5 m Optional ...

Page 36: ...PG Blue Black White Red Black Green GND 24V Orange black 2 Orange red 2 Yellow black 1 Yellow red 1 White black 1 White red 1 Light blue black 1 Light blue red 1 Motor drive power cutoff circuit Controller Connected to teaching pendant or PC Input power supply 24 VDC 24V 0V FG Host system PLC I O flat cable Refer to 4 3 Connecting the I O Cables for the connection of I O signals PORT switch Actuat...

Page 37: ...be sure to install it on the positive side of the 24 V power supply Keep the negative side of the 24 V power supply connected without cutting it off with a relay If a relay is installed on both the positive and negative sides an ABS error may generate b Connect a surge killer to the relay contact Chattering of the relay may have negative effect on the controller Connect a surge killer to prevent m...

Page 38: ...device to these terminals Note The rush current must be 8 A or less The rated current is 2 A The contact for the EMG switch on the teaching pendant is provided by the S1 S2 terminals Note When connecting the teaching pendant to a SIO converter the contact for the EMG switch on the teaching pendant is provided by the EMG1 EMG2 terminals on the SIO converter 24V 0V FG S1 S2 MPI MPO 24V N FG S1 S2 MP...

Page 39: ...1B EMGS Available on RCP2 C Not used on RCP2 CG 12B 13B 13A 13B 1A 1B Controller end PIO signal abbreviation 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 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3 Host system PLC end Output side 24 V 0 V Start Command position 1 Command position 2 C...

Page 40: ...B MOVE 9B PEND 10B HEND 11B EMGS Available on RCP2 C Not used on RCP2 CG 12B SRDY 13B ALM 13A 13B 1A 1B 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 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3 Controller end PIO signal abbreviation Output side 24 V 0 V Command position 1 Command posi...

Page 41: ...t used on RCP2 CG 12B MOVE 13B ALM 13A 13B 1A 1B 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 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3 Controller end PIO signal abbreviation Output side 24 V 0 V Command position 1 Command position 2 Command position 4 Command position 8 Command po...

Page 42: ...B PM8 7B ZONE1 8B ZONE2 9B PEND 10B HEND 11B EMGS Available on RCP2 C Not used on RCP2 CG 12B SRDY 13B ALM 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 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3 Controller end PIO signal abbreviation Output side 24 V 0 V Command position 1 Command p...

Page 43: ... 11A SON 12A RES JOG 13A 1B 2B 3B PM1 4B PM2 5B PM4 6B PM8 7B MODES 8B MOVE 9B PEND WEND 10B HEND 11B EMGS Available on RCP2 C Not used on RCP2 CG 12B SRDY 13B ALM 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 Yellow 2 Green 2 Blue 2 Purple 2 Gray 2 White 2 Black 2 Brown 3 Red 3 Orange 3 Yellow 3 Green 3 Blue 3 Controller end PIO signal abbre...

Page 44: ...e A B2 VMM Black Motor power line B3 B Green Motor drive line phase B Housing 1 1318119 3 AMP Housing SLP 06V J S T Mfg Receptacle contact 1318107 1 Socket contact BSF 21T P1 4 4 1 6 3 2 1 3 A B CN2 CN1 CB RCP2 MA Blue Black White Red Black Green yellow 3 A VMM B A VMM B A1 A2 A3 B1 B2 B3 A VMM A B VMM B 1 2 3 4 5 6 Red Black Blue Green yellow 3 Black White Controller end CN2 pin assignments Actua...

Page 45: ...VS J S T Mfg Contact SPHD 001T P0 5 Housing XMP 18V J S T Mfg Contact BXA 001T P0 6 Retainer XMS 09V 1 2 15 16 CN2 CN1 CB RCP2 PA Controller end CN2 pin assignments Actuator end CN1 pin assignments CN2 CN1 Purple White with purple Blue White with blue Yellow White with yellow Green BK BK ENA ENA ENB ENB 5V GND N C N C N C F G 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 46: ...ed 1 Yellow black 1 BK BK ENA ENA ENB ENB 5V GND N C N C N C F G 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ENA ENA ENB ENB GND 5V BK BK F G Orange red 2 Orange black 2 Drain Reserved Reserved 1 10 9 18 Cable color Signal name Robot Standard Red Gray Brown Green Purple Pink Orange Blue Drain Reserved Reserved Cable color Robot White red 1 White black 1 Yell...

Page 47: ...D 5V 2 3 4 5 6 Pin No SGA SGB 5V EMGS EMGA 24V Brown Green 1 2 3 4 5 6 Pin No 7 8 Yellow Orange Black Red Blue GND EMGB FG Black 1 2 3 6 8 5 Pin assignments of the cable end connector RS485 conversion adapter end Controller end CB RCA SIO Signal name Signal name Cable color Cable color Shielded Shorting wire UL1004AWG28 black Shielded not connected ...

Page 48: ... boundaries for the second zone output signal are specified in user parameter Nos 23 and 24 4 Teaching This pattern allows for normal positioning operation as well as jogging and writing of current position to a specified position using I Os Switching between the normal positioning mode and teaching mode is effected by the MODE input signal The mode switching completion output has been added to in...

Page 49: ...tart operation Moving MOVE This signal turns ON while the actuator is moving and turns OFF while it is stopped It is used for operation check and also to determine whether the load is contacted during push hold operation Position complete PEND This signal turns ON when the target position was reached and the actuator has entered the specified in position range It is used to determine whether posit...

Page 50: ...E HOME 11A Brown 2 SON STP SON SON 12A Input Red 2 RES RES RES RES JOG 13A Orange 2 Not used 1B Lower stage Yellow 2 Not used 2B Green 2 Not used 3B Blue 2 PM1 PM1 PM1 PM1 PM1 4B Purple 2 PM2 PM2 PM2 PM2 PM2 5B Gray 2 PM4 PM4 PM4 PM4 PM4 6B White 2 PM8 PM8 PM8 PM8 PM8 7B Black 2 PEND ZONE1 PM16 ZONE1 MODES 8B Brown 3 HEND MOVE PM32 ZONE2 MOVE 9B Red 3 ZONE1 PEND PEND PEND PEND WEND 10B Orange 3 AL...

Page 51: ... assignments for a PNP controller 5 2 1 External Input Specifications Item Specification Number of input points 10 points Input voltage 24 VDC 10 Input current 7 mA point Leak current 1 mA or less point Insulation method Photocoupler Internal circuit configuration NPN specification PNP specification P24V R 560 Ω R 3 3 kΩ R 22 kΩ C 0 1 µF N R 560 Ω R 3 3 kΩ R 22 kΩ C 0 1 µF Controller Controller Ex...

Page 52: ...Maximum current 20 mA point Residual voltage 2V or less Insulation method Photocoupler Internal circuit configuration NPN specification PNP specification N P24V N P24V Controller External power supply 24V Internal circuit Each output Load Load Controller External power supply 24V Internal circuit Each output Load Load ...

Page 53: ...nal is OFF the controller will automatically perform home return operation before positioning to the target position Servo ON SON The servo remains ON while this signal is ON Use this signal if servo ON OFF control must be performed by the PLC as part of a safety circuit covering the entire system User parameter No 21 that defines whether to enable or disable this signal must always be set Set 0 E...

Page 54: ...peration mode after confirming the OFF status of the MODES output signal Note 2 The normal operation mode cannot be restored unless all of the PWRT JOG and JOG input signals are OFF 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 th...

Page 55: ...ent command turn ON the alarm reset signal while this signal is OFF to cancel the remaining movement The STP signal can be used for the following purposes 1 Provide a low level safety measure to stop the axis while the servo is ON such as a sensor that detects a person approaching the system 2 Prevent contact with other equipment 3 Perform positioning based on sensor or LS detection Note 1 If the ...

Page 56: ... issued by turning ON the start signal the PEND signal will turn OFF It will turn ON again when the deviation from the target position falls within the in position range Once turned ON the PEND signal will not turn OFF even when the position deviation subsequently exceeds the in position range Note If the start signal remains ON the PEND signal will not turn OFF even when the deviation from the ta...

Page 57: ...mediate point or as a simple ruler The ZONE1 signal will turn ON when the current position is inside the range specified by user parameter Nos 1 and 2 and turn OFF if the current position is outside this range If the 2 zone output signals pattern is selected the ZONE2 signal will turn ON OFF in the same manner with respect to the range specified by user parameter Nos 23 and 24 Note The ZONE signal...

Page 58: ...rogress following an input of the home return signal ON OFF ON OFF OFF Home return has completed following an input of the home return signal OFF ON ON ON OFF Actuator is moving in the positioning push hold mode ON OFF ON ON OFF Actuator is paused in the positioning push hold mode OFF OFF ON ON OFF Positioning has completed in the positioning mode OFF ON ON ON ON Actuator has stopped after contact...

Page 59: ...0 0 1 0 2 10 100 0 3 0 0 1 0 x x x x x x x x x 15 x x 100 x x 100 x x 0 3 x x 0 x x 0 1 x x 0 When data is entered in the position column of the position data table the default values will be automatically entered in the remaining columns Change the default values as necessary To change a default value change the corresponding parameters starting with Default The default values vary depending on t...

Page 60: ...ter the speed at which the actuator will be moved in mm sec The default value varies depending on the actuator type 4 Acceleration deceleration ACC Enter the acceleration deceleration at which the actuator will be moved in G The default value varies depending on the actuator type 5 Push Push Select the positioning mode or push hold mode The default value is 0 0 Positioning mode Normal operation Ot...

Page 61: ...e from the target in the push hold mode in mm Fig B If the push direction corresponds to the negative direction along the displayed coordinate axis add a minus sign to the entered value Fig A Fig B 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 acc...

Page 62: ... limiting value Low speed type 70 Medium speed type 70 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 The maximum current limiting value is shown in the above graphs The minimum value is 20 180 160...

Page 63: ...only If the push force is too small malfunction may occur during push hold operation due to slide resistance etc so exercise caution The maximum current limiting value is shown in the above graphs The minimum value is 20 400 300 200 100 0 400 300 200 100 0 20 30 40 50 20 30 40 50 60 70 200 150 100 50 0 20 30 40 50 60 70 Low speed type Medium speed type Push force N Push force N Current limiting va...

Page 64: ...mall malfunction may occur during push hold operation due to slide resistance etc so exercise caution The maximum current limiting value is shown in the above graphs The minimum value is 20 900 800 700 600 500 400 300 200 100 0 500 400 300 200 100 0 20 30 40 50 60 65 20 30 40 50 60 70 300 250 200 150 100 50 0 20 30 40 50 60 70 Low speed type Medium speed type Push force N Push force N Current limi...

Page 65: ...lding the load in position while pushing it Warning The actuator continues to push the load at the push force at standstill determined by the current limiting value Since the actuator is not inactive exercise due caution when handling the machine in this condition The push speed is set as follows in accordance with the speed set in the position data table Set speed 20 mm sec or more Less than 20 m...

Page 66: ... actuator will push the load within the positioning band The position complete output will remain ON and the completed position number will be output continuously b Load moves in the opposite direction Actuator is pushed back by the reactive force of the load If the actuator is pushed back after the position complete output has turned ON because the actuator thrust is smaller than the reactive for...

Page 67: ...lement each speed change must be set 6 2 4 Operation at Different Acceleration and Deceleration Settings The actuator will accelerate and decelerate at different speeds if 1 is entered under Acceleration only MAX in the position data The acceleration will conform to the maximum acceleration set according to the load while the deceleration will conform to the value entered in Acceleration decelerat...

Page 68: ...e to a stop while turning it ON will allow the actuator to complete the remaining operation The remaining movement of the actuator can be cancelled by turning ON the reset input during pause the movement will be cancelled upon rise of the reset input signal Note If parameter No 25 IO pattern is set to 0 Conventional the reset input is not available ON ON OFF Pause signal Actuator operation Pause s...

Page 69: ...ome return is not required when the power is turned on This is because once home return is executed the current position will be retained even after the power is turned off On the absolute controller home return is required only after the controller is started for the first time or when the current position has been lost due to low battery voltage etc There are two ways to execute home return z No...

Page 70: ...in accordance with ON OFF of the operation mode input Operation mode input ON OFF Mode Teaching mode Positioning mode Jog input Pause input Jog input Reset input Current position write input Start input PIO Write completion output Position complete output Among the PIO signals use the jog jog inputs to move the actuator and use the current position write input to write the current actuator positio...

Page 71: ...C or teaching pendant and set the following parameters as the minimum initial settings Parameter No 15 Pause input disable selection Parameter No 21 Servo ON input disable selection Parameter No 25 PIO pattern selection For details refer to 8 Parameters 7 Cancel the emergency stop or supply the motor power 8 Turn ON the Pause and servo ON input at the PIO connector if these signals are enabled 9 T...

Page 72: ...onventional or 2 64 point positioning the servo ON input and ready output are not available ALM EMGS enabled only on RCP2 C controllers STP SON SRDY PEND Power ON Alarm output RDY lamp Emergency stop ALM lamp Pause input Servo ON input RUN lamp Ready output Position complete output Emergency stop is not actuated Motor power is not cut off Pause has been cancelled Movement command home return posit...

Page 73: ...rs 8 Reset the alarm z Issuing a command from the PLC If the PIO pattern is 0 Conventional input the start signal CSTR for at least 6 msec If the PIO pattern is other than 0 Conventional input the reset signal RES for at least 6 msec z To reset the alarm from the PC or teaching pendant refer to the operation manual for the PC or teaching pendant 9 Cancel the emergency stop or connect the motor dri...

Page 74: ...en the actuator moves to the target position Execute home return first and then move to the target position The home return completion HEND will turn ON at the home position and upon reaching the target position the position complete PEND and completed position output PM1 to PM8 will turn ON To stop the actuator at the home position set the target position to 0 z When the PIO pattern is other than...

Page 75: ...by setting 0 as the target position z When the PIO pattern is other than 0 Conventional Input the home return signal HOME When home return is complete the home return completion HEND and position complete PEND will turn ON Note As in the conventional pattern you can also execute home return by selecting and inputting a desired command position number in which a target position is registered and th...

Page 76: ...move to the target position if the set position is other than 0 Make sure the PLC can recognize that the actuator is stopped at the home position 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 Command position PC1 PC2 Start CSTR Position comple...

Page 77: ...n 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 Home return HOME Position complete PEND Moving MOVE Home return completion HEND Actuator movement Mechanical end Stops at the home position ...

Page 78: ...eration Push Positioning band Acceleration only MAX 0 0 100 0 3 0 0 1 0 1 150 200 0 3 0 0 1 0 x x x RCP2 controller P L C 5 2 1 8 7 3 6 9 4 PIO Signal name Start Command position 1 Command position 2 Command position 4 Command position 8 Pause Reset Servo ON Completed position 1 Completed position 2 Completed position 4 Completed position 8 Position complete Home return completion Zone Alarm Ready...

Page 79: ...er 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 The start signal must be turned OFF with the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal ...

Page 80: ...ion 1 Completed position 2 Completed position 4 Completed position 8 Position complete Home return completion Zone Alarm Ready Moving Category Input Output Reference flow Select enter command position 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Start input ON Movement to position 1 starts Completed position OFF Position complete output OFF Moving output ON Start input OFF Position complete output ON ...

Page 81: ...tion Note When the start signal turns ON the position complete output will turn OFF and the moving output will turn ON The start signal must be turned OFF with the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal remains ON If the start input remains ON as shown below the position complete output will not turn ON even when the actuato...

Page 82: ...15 14 11 6 3 16 12 8 4 PIO Signal name Start Command position 1 Command position 2 Command position 4 Command position 8 Pause Reset Servo ON Completed position 1 Completed position 2 Completed position 4 Completed position 8 Position complete Home return completion Zone Alarm Ready Moving Category Input Output Reference flow Select enter command position 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 S...

Page 83: ... output will turn ON The start signal must be turned OFF with the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal remains ON If the actuator has missed the load the position complete output will not turn ON as shown below The completed position will be output and the moving output will turn OFF Command position Start Position complet...

Page 84: ...nt to position 1 is output Command position 2 should be entered while the actuator is moving to position 1 RCP2 controller P L C 11 9 5 2 1 6 8 13 12 10 7 3 14 4 PIO Signal name Start Command position 1 Command position 2 Command position 4 Command position 8 Pause Reset Servo ON Completed position 1 Completed position 2 Completed position 4 Completed position 8 Position complete Home return compl...

Page 85: ...rns 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 The start signal must be turned OFF with the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal remains ON Speed Position 1 Position 2 Position 1 T1 T1 Position ...

Page 86: ...on to 0 1 G RCP2 controller P L C 5 2 1 7 6 3 8 4 PIO Signal name Start Command position 1 Command position 2 Command position 4 Command position 8 Pause Reset Servo ON Completed position 1 Completed position 2 Completed position 4 Completed position 8 Position complete Home return completion Zone Alarm Ready Moving Category Input Output Reference flow Select enter command position 1 1 2 3 4 5 6 7...

Page 87: ...ill turn OFF and the moving output will turn ON The start signal must be turned OFF with the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal remains ON If the start input remains ON as shown below the position complete output will not turn ON even when the actuator movement is completed Speed Position 1 Position 1 T1 Command position...

Page 88: ... Position complete Home return completion Zone Alarm Ready Moving Category Input Output Reference flow Select enter a desired command position 1 2 3 4 5 6 7 8 9 10 11 12 Start input ON Completed position OFF Position complete output OFF Moving output ON Start input OFF Moving output OFF Movement to the selected position completes Position complete output ON Completed position is output Movement to...

Page 89: ...s turned OFF while the start signal remains ON The remaining movement can be cancelled by turning ON the reset input during pause The controller will detect a rise of the reset signal and cancel the remaining movement If parameter No 25 I O pattern is set to 0 Conventional the reset input is not available Command position Start Position complete Completed position Pause Moving Actuator movement Sp...

Page 90: ...r No 25 PIO pattern is set to 2 64 point positioning or 4 Teaching RCP2 controller P L C 5 2 1 9 8 3 7 6 10 4 PIO Signal name Start Command position 1 Command position 2 Command position 4 Command position 8 Pause Reset Servo ON Completed position 1 Completed position 2 Completed position 4 Completed position 8 Position complete Home return completion Zone Alarm Ready Moving Category Input Output ...

Page 91: ... The start signal must be turned OFF with the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal remains ON Example of other zone output Zone output at 120 or more Zone output at 40 or less Zone boundary Maximum stroke length Zone boundary 40 Zone boundary 120 Zone boundary 0 Command position Start Position complete Completed position Z...

Page 92: ... position 4 Completed position 8 Position complete Home return completion Zone Alarm Ready Moving Category Input Output Reference flow Select enter command position 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Start input ON Movement to position 1 starts Completed position OFF Position complete output OFF Moving output ON Start input OFF Position complete output ON Completed position 1 is output Movin...

Page 93: ...h the confirmation that the moving output has turned ON position complete output has turned OFF while the start signal remains ON If the start input remains ON as shown below the position complete output will not turn ON even when the actuator movement is completed Note 2 When a soft limit is reached as a result of repeated incremental moves the actuator will stop at that position and the position...

Page 94: ...tuator will move to the position corresponding to the initial position plus the increment x number of times the signal was input Example If the start signal for movement to position 2 is input twice while the actuator is moving to position 1 the actuator will move to the position 50 mm from the home 2 Note on push hold operation If the start signal is input with an incremental position number sele...

Page 95: ... actuator type is shown below RC model Speed type Lead mm Maximum error range mm Low speed 3 0 00375 Medium speed 6 0 0075 RCP2 SA5 SA6 SS R High speed 12 0 015 Low speed 5 0 00625 Medium speed 10 0 0125 RCP2 SM SMR High speed 20 0 025 Low speed 2 5 0 003125 Medium speed 5 0 00625 RCP2 RSA RXA High speed 10 0 0125 Low speed 4 0 005 Medium speed 8 0 01 RCP2 RMA SA7 High speed 16 0 02 Example If an ...

Page 96: ...peration The actuator is caused to move using the jog input or jog input and the current position is read into position No 1 RCP2 controller P L C 4 2 4 1 7 5 1 4 1 3 6 PIO Signal name Command position 1 Command position 2 Command position 4 Command position 8 Operation mode Jog Pause Current position write Start Servo ON Jog Reset Completed position 1 Completed position 2 Completed position 4 Com...

Page 97: ...l be written to the selected command position number When the writing is complete the write completion WEND output will turn ON To check if the writing has completed check if the write completion WEND output is ON Turning OFF the current position write PWRT input will cause the write completion WEND output to turn OFF Note Be sure to enable the pause signal using user parameter No 15 by setting th...

Page 98: ...characteristics 10 b Default positioning band in position mm 0 10 11 b Default acceleration only MAX flag 0 12 b Current limiting value at standstill during positioning Set individually in accordance with the actuator characteristics 13 b Current limiting value during home return Set individually in accordance with the actuator characteristics 14 Reserved for future extension 15 c Pause input disa...

Page 99: ... No 4 negative side 0 3 z Zone boundary Set the zone in which a zone output signal ZONE1 or ZONE2 will turn ON Note ZONE2 is enabled only when 2 zone output signals is selected as the PIO pattern The zone signal turns ON only when the current coordinate position is inside the negative boundary and positive boundary settings The positive and negative boundaries for the ZONE1 signal are set in param...

Page 100: ...ing the actuator Note If the home return offset has been changed the soft limit parameters must also be adjusted accordingly 8 3 2 Parameters Relating to the Actuator Operating Characteristics z PIO jog speed Define the speed at which the actuator will be jogged using PIO in the teaching mode The factory setting is 100 mm sec Set an optimal value for the specific application z Default speed The fa...

Page 101: ...s used as a judgment condition when determining if the load was contacted and the push hold operation has completed The push hold operation is judged complete if the current limiting value set in the position table has been maintained for the period set in parameter No 6 Set an optimal value by considering the shape and strength of the load as well as the current limiting value The minimum setting...

Page 102: ... the basis of operation so be sure to set this parameter at the beginning The factory setting is 0 Conventional Parameter No 25 setting Feature of PIO pattern 0 Conventional This pattern is compatible with the pin assignments of the RCP controller 1 Standard All functions of the RCP controller are available plus the home return command input servo ON input reset input moving output and ready outpu...

Page 103: ...speed The factory setting is 38400 bps z Minimum delay time for slave transmitter activation This parameter defines the minimum delay until the controller s transmitter will be activated after completion of command reception when serial communication is performed using the PLC s communication module The factory setting is 5 msec but other necessary delay time must be set in parameter No 17 if the ...

Page 104: ...e PC etc Teaching pendant RCA T TD Optional Cable length 5 PC software RCB 101 MW Optional RS232C cross cable Provided by the user Components SIO converter with built in terminal resistor RCB TU SIO A Vertical type RCB TU SIO B Horizontal type FG 0V 24V Input power supply Controller power supply Terminal resistor R 220 Ω Controller link cable CB RCB CTL002 ADRS switch 0 Controller 1 ADRS switch 1 ...

Page 105: ...and conversion circuit 0V Negative side of the 24 V power supply FG FG of the 24 V power supply Note 0V connects to pin 7 GND in the controller s communication connector z Connection method Use a connection cable satisfying the following specifications Item Specification Applicable wire size Single wire φ 0 8 to 1 2 mm Stranded AWG size 20 to 18 end is soldered Stripped wire length 10 mm 2 Link co...

Page 106: ...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 4 Mini DIN 8 pin connector A connection port with the teaching pendant 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 Li...

Page 107: ...rm that the addresses are not duplicated 9 5 Connection Cables z Controller link cable Model CB RCB CTL002 Reference Connection diagram for RS232C cross cable SIO converter end PC end Signal No No Signal SGA 1 1 SGA SGB 2 2 SGB 5V 3 3 GND 4 4 EMGA 5 24V 6 GND 7 EMGB 8 Signal No 1 RD 2 SD 3 ER 4 SG 5 DR 6 RS 7 CS 8 9 No Signal 1 2 RXD 3 TXD 4 DTR 5 SG 6 DSR 7 RTS 8 CTS 9 Adjust the arrow to a desir...

Page 108: ...20 Ω with E Con connector Of the above 2 3 and 4 are provided for the same number as the controller link cables Therefore not all units are needed when multiple axes are used SIO converter Two paired shielded cable Recommended brand Taiyo Electric Wire Cable HK SB 20276XL 2PX22AWG Four way junction AMP 5 1473574 4 A B EMG2 EMG1 24V 0V FG 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 7 1 2 7 SGA SGB GND SGA ...

Page 109: ...les to prevent accidental power connection due to a sneak current path g Check the I O signals h Check the noise elimination measures grounding installation of surge killer etc i Review the events leading to the occurrence of problem as well as the operating condition at the time of occurrence j Check the serial numbers of the controller and actuator k Analyze the cause l Take action Please check ...

Page 110: ...rence in alarm reset method from the PLC If the PIO pattern is 0 Conventional actuate an emergency stop or cut off the motor drive power first and then input the start signal CSTR for at least 6 msec Thereafter cancel the emergency stop or connect the motor drive power This operation is effective on software version AD000007 or later supporting the absolute specification If the PIO pattern is othe...

Page 111: ...onvolatile memory data write error F7 z z z Relating to position data parameter Data error at execution of bank 31 B1 Data error at execution of bank 30 B0 z z Excitation detection error B8 z z z z Excessive actual speed C0 z z z Relating to supply voltage Excessive motor supply voltage C9 Excessive control supply voltage CC Drop in control supply voltage CE z z z Overheating CA z z z Deviation ov...

Page 112: ...rror in the serial communication using the PLC s communication module Cause Undefined command or out of range data Action Review the transmitted data and correct the format 65 EEPROM write timeout Cause Writing of parameter or position data to the nonvolatile memory area does not complete within 200 ms This alarm will not generate in normal operation Action Do not write data from the PC or teachin...

Page 113: ...larms Code Error name Cause Action B0 Bank 30 data error Cause Data in the parameter area is outside the input range or invalid This alarm will not generate in normal parameter input operation but may occur during serial communication using the PLC s communication module Action Transfer data after confirming that the parameter values are valid B1 Bank 31 data error Cause 1 A movement command was i...

Page 114: ... mechanical parts 4 If the load is normal cut off the power and move the actuator by hand to check the slide resistance If the actuator is suspected to be the cause please contact IAI C9 Excessive motor supply voltage This alarm indicates that the motor supply voltage is excessive 24V 20 28 8V or more Cause 1 High voltage of the 24 V input power supply 2 Faulty part inside the controller Action Ch...

Page 115: ...as moved by hand and the followable speed was exceeded while the power supply was cut off 5 The encoder cable or battery cable became open while the power supply was cut off Action Check the cables for loose connections Reset the alarm Then execute home return after confirming that the ALM signal has turned ON again If the battery voltage is low supply the power for at least 48 hours EF Absolute e...

Page 116: ...r has overflowed Cause 1 The speed dropped during movement due to the effect of an external force etc 2 The pole sense detection operation after power on is unstable Action 1 Check the load conditions such as whether the load is contacting a surrounding object or the brake is disengaged and then correct the abnormality if any 2 An overload condition is suspected so review the load weight Reconnect...

Page 117: ...ion controller is not operating properly Cause 1 Malfunction due to the effect of noise etc 2 Faulty FPGA 3 Defective board installation inside the controller Action Reconnect the power If the error persists investigate possible noise sources If the cause cannot be specified please contact IAI ...

Page 118: ...riate values again 11F Absolute position too small The minimum movement toward the target position is determined by the lead length of the drive system and resolution of the encoder This message indicates that the entered target value is smaller than the minimum movement Example If the lead length is 20 mm the encoder s resolution is 800 pulses and accordingly the minimum movement becomes 20 800 0...

Page 119: ...ontrollers are controlled by serial communication Action 1 Adjust the wiring in a manner eliminating the effect of noise and review the installation of equipment etc 2 Change the slave numbers to avoid duplication If the message is still displayed after taking the above actions please contact IAI 307 Memory command refused This message indicates that the command was refused in the serial communica...

Page 120: ...connected properly probably the controller is faulty Please contact IAI Note If the 24 V power supply is connected in reverse the controller may not fail immediately but its service life will likely be shortened z Only the RDY lamp illuminates when the servo ON signal is input after the power was input The servo does not turn ON Cause 1 Contact failure of the flat cable 2 Faulty controller Check t...

Page 121: ...n occurs when the actuator is stopped Cause The slider is receiving an external force Action If the external force cannot be removed increase the value set in user parameter No 12 Current limiting value at standstill during positioning Increasing this value will cause the holding torque at standstill to increase so do not increase the parameter setting above 70 z The actuator overshoots when decel...

Page 122: ...ead 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 2 Please contact IAI ...

Page 123: ...positions Positioning circuit for position 1 When position 1 is set as the home Home return request Home return request Home return start pulse Auxiliary home return start pulse G F G F G Positioning start request to position 1 I H I H Positioning start request to position 1 I Positioning start pulse to position 1 home Auxiliary positioning start pulse to position 1 home The positioning start requ...

Page 124: ...se the sequence stops in the middle as implemented in this circuit even when a problem occurs the cause can be identified more easily Create for the number of positions Command position number output encoding circuit J O R Auxiliary start position for positioning to other position Set signal for other position S R S Position 1 set Position 2 set R Auxiliary start position for positioning to other ...

Page 125: ... position 2 PC1 PC2 Position 6 set signal Position 3 set signal PC4 PC8 Command position 4 Command position 8 Start signal circuit J Timer 2 Waiting for start O Start command for positioning to other position Timer 2 Start signal 5 msec or more Must be longer than the PLC s scan time CSTR ...

Page 126: ...114 Appendix Recording of Position Data Table Recorded date No Position mm Speed mm sec Acceleration deceleration G Push Positioning band mm Acceleration only MAX 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 127: ...selected No Position mm Speed mm sec Acceleration deceleration G Push Positioning band mm Acceleration only MAX 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 ...

Page 128: ...9 b Default acceleration deceleration G 10 b Default positioning band in position mm 11 b Default acceleration only MAX flag 12 b Current limiting value at standstill during positioning 13 b Current limiting value during home return 14 Reserved for future extension 15 c Pause input disable selection 0 Enable 1 Disable 16 c Serial communication speed bps 17 c Minimum delay time for slave transmitte...

Page 129: ...67 9912 New Jersey Office 7 South Main St Suite F Marlboro NJ 07746 TEL 732 683 9101 FAX 732 683 9103 Home page 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 2004 Jul IAI Corporation All rights reserved ...

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