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Actuator with integrated controller
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ERC2
Actuator with Integrated Controller
(SIO Type)
Operation Manual
Seventh Edition

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Summary of Contents for IAI ERC2

  • Page 1 ERC2 Actuator with Integrated Controller (SIO Type) Operation Manual Seventh Edition...
  • Page 3 Information contained in this Operation Manual is subject to change without notice for the purpose of product improvement. If you have any question or comment regarding the content of this manual, please contact the IAI sales office near you. Using or copying all or part of this Operation Manual without permission is prohibited.
  • Page 4 CAUTION 1. Using Multiple 24-V Power Supplies If multiple 24-V power supplies are used, always connect the 0-V lines of all power supplies. If not, damage to the controller board, SIO converter or other components may occur. [Connection Example] 24-V power supply converter PIO unit Actuator 1...
  • Page 5 To support these new functions, the communication protocol has been changed to a general Modbus- compliant protocol. Accordingly, the PC software programs and teaching pendants that have been used with the ERC series are no longer compatible with the ERC2 series. Select a compatible program or teaching pendant from among the models listed below.
  • Page 6 CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.

  • Page 7: Table Of Contents

    Table of Contents Safety Guide ..............................1 Overview ..............................9 Introduction ..........................9 Key Features and Functions...................... 10 Differences from Air Cylinder Control ..................11 Meaning of the Model Number ....................13 Specifications..........................14 1.5.1 Correlation Diagrams of Speed and Payload Capacity – Slider Type ......15 1.5.2 Correlation Diagrams of Speed and Payload Capacity –...
  • Page 8 Greasing the Guide (Slider Type) .................... 108 Greasing the Ball Screw (Slider Type)..................110 Greasing the Rod Slide Surface ....................111 Motor Replacement Procedure....................112 Operation Examples .......................... 114 10. Appendix ............................115 .......................... 10.1 External Dimensions .......................... 10.1.1 ERC2-SA6C .......................... 10.1.2 ERC2-SA7C...
  • Page 9 .......................... 10.1.3 ERC2-RA6C .......................... 10.1.4 ERC2-RA7C ........................10.1.5 ERC2-RGS6C ........................10.1.6 ERC2-RGS7C ........................10.1.7 ERC2-RGD6C ........................10.1.8 ERC2-RGD7C 10.2 Recording of Position Table ........................ 10.3 Parameter Records ..........................Change History..........................125...

  • Page 11: Safety Guide

    Safety Guide Safety Precautions for Our Products...
  • Page 12 Operation Description Description Transportation When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.
  • Page 13 Operation Description Description Installation (2) Cable Wiring and Start for connecting between the actuator and controller, and for the teaching tool. Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.
  • Page 14 Operation Description Description Installation (4) Safety Measures and Start When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within t...
  • Page 15 Operation Description Description Trial Operation When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
  • Page 16 Operation Description Description Maintenance When the work is carried out with 2 or more persons, make it clear who is and Inspection to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Perform the work out of the safety protection fence, if possible.
  • Page 17 Alert Indication...

  • Page 19: Overview

    This product retains all benefits of the conventional ERC series, while incorporating new features that provide greater convenience and enhanced safety to the users. Among the ERC2 Series actuators, this product can be operated via serial communication in the position number specification mode or the direct numerical specification mode.

  • Page 20: Key Features And Functions

    Key Features and Functions (1) Input/output of control signals by means of RS485 serial communication (conforming to the Modbus protocol) (2) 64 positioning points (3) Variable zone output boundaries Before, zone output boundaries were set by parameters and therefore fixed. For greater convenience, this product permits setting of zone output boundaries in the position table.

  • Page 21: Differences From Air Cylinder Control

    Differences from Air Cylinder Control This section explains the key differences between an air cylinder and this controller for users who are familiar with air cylinders but have never used a motorized cylinder before. Refer to the table below to perform appropriate controls. Item Air cylinder This controller...
  • Page 22 Item Air cylinder This controller Position check Determined using a reed Immediately after the power has been turned on, the current upon power on switch or other external position is indeterminable because no mechanical detection sensor. coordinates are stored in the controller. After the power is turned on, therefore, a home return command must always be issued to establish coordinates.

  • Page 23: Meaning Of The Model Number

    Meaning of the Model Number ERC2-SA6C-I-PM-12-300-SE-S-NM <Series name> <Options> Blank: No option With brake <Type> NM: Reversed-home Slider type specification SA6C FT: Foot bracket (Specified SA7C only for rod types.) Rod type <Extension cable length> RA6C Blank: No cable RA7C...

  • Page 24: Specifications

    Specifications Payload capacity (Note Rated acceleration Stroke (mm) and maximum speed (mm/sec) (Note 1) Horizontal Vertical Horizontal Vertical Model (Note 1) The figures in blank bands indicate the maximum speeds for respective strokes. The maximum speeds during vertical operation are shown in parentheses. (Note 2) The payload capacity is based on operation at the rated acceleration.

  • Page 25: Correlation Diagrams Of Speed And Payload Capacity - Slider Type

    1.5.1 Correlation Diagrams of Speed and Payload Capacity – Slider Type Horizontal installation Vertical installation Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) (Note) In the above graphs, the number after each type name indicates the lead.

  • Page 26: Correlation Diagrams Of Speed And Payload Capacity - Rod Type

    1.5.2 Correlation Diagrams of Speed and Payload Capacity – Rod Type Horizontal installation Vertical installation Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) Speed (mm/sec) (Note) In the above graphs, the number after each type name indicates the lead.

  • Page 27: The Sound Pressure Level Of This Product Does Not Exceed 70 Db

    Load Applied to the Actuator (1) Slider type Keep the load applied to the slider below the value stated in the applicable specification item. In particular, pay attention to the moment applied to the slider, allowable overhang length and payload capacity.

  • Page 28: 1.6 Warranty

    1.6 Warranty 1 Warranty Period One of the following periods, whichever is shorter: 18 months after shipment from our company 12 months after delivery to the specified location 2 Scope of Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer.
  • Page 29 5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications (1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc.

  • Page 30: Transportation And Handling

    When unpacking, exercise due caution not to let the actuator drop and sustain damage to its mechanism. If the actuator is damaged during the shipment or any of the items is found missing, please contact IAI’s Technical Support immediately.

  • Page 31: Installation Environment And Noise Elimination

    Installation Environment and Noise Elimination Pay due attention to the installation environment of the controller. 1.8.1 Installation Environment The installation environment must satisfy the following conditions: Use environment/condition Not exposed to direct sunlight. The actuator is not subject to irradiated heat from a large heat source, such as a heat treatment furnace.

  • Page 32: Power Supply

    1.8.3 Power Supply The control/motor-drive power supply specification is 24 VDC 10% (2 A max). 1.8.4 Noise Elimination This section explains how to eliminate noise in the use of the controller. (1) Wiring and power supply [1] Provide a dedicated class D grounding using a wire with a size of 0.75 mm or larger.
  • Page 33 (2) Noise sources and elimination Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular concern when building a system. Noise from these sources can be eliminated by implementing the measures specified below. [1] AC solenoid valves, magnet switches and relays Measure: Install a surge absorber in parallel with the coil.

  • Page 34: Cabling

    Do not cut the cable for the purpose of extension, length reduction or reconnection. If you intend to change the cable layout, please consult IAI.
  • Page 35 Prohibitions/Notes on Handling Cables When designing an application system using this actuator, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway system. This section explains prohibited handling of cables. Read the information carefully to connect the cables properly. Do not let the cable flex at a single point.
  • Page 36 Notes on use of cable tracks Robot cable Always use a robot cable for Bending radius (r) each extension Use a cable track with a bending radius (r) of 50 mm or more. PIO line, communication line, power and driving lines are to be put separately from each other and do not tie them together.

  • Page 37: Installation

    Installation Name of Each Part 2.1.1 Slider Type (SA6C/SA7C) Screw cover Coupling bolt Right Non-motor Motor end Side cover Left Front bracket Motor bracket Rear cover Rear bracket Slider Motor cover Cable Base Bottom 2.1.2 Rod Type (RA6C/RA7C) Coupling bolt Right Non-motor end Motor end...

  • Page 38: Rod Type (Ra6C/Ra7C)

    2.1.3 (1) Rod Type with a Single Guide (RGS6C/RGS7C) Coupling bolt Right Motor end Non-motor end Left Rear bracket Guide bracket Guide bearing Guide rod Motor bracket Rear cover Frame Cable Motor cover Bottom (2) Rod Type with Double Guides (RGD6C/RGD7C) Mounting bracket Guide bearing Guide rod...

  • Page 39: Installation

    Installation 2.2.1 Slider Type Installing the actuator The actuator-mounting surface must be a machined surface or have an equivalent flatness. The side and bottom faces of the actuator base are parallel with the guides. If high slide precision is required, install the actuator by using these surfaces as references.

  • Page 40: Rod Type

    2.2.2 Rod Type A rod-type actuator can be installed in the following two ways: Affixing with a flange Install the actuator by tightening from the motor end side with hex cap bolts using the holes provided in the flange. Caution: If the actuator is installed horizontally, exercise caution not to let the actuator receive excessive forces.
  • Page 41 Affixing with foot brackets (optional) If optional foot brackets are used, install the foot brackets using hex cap bolts. Foot-bracket tightening bolts Model Nominal thread size Tightening torque RA6C RGS6C 5.4 N m (0.55 kgf-m) RGD6C RA7C RGS7C 11.5 N m (1.17 kgf-m) RGD7C...

  • Page 42: Installing The Load

    2.2.3 Installing the Load Slider Type Four tapped holes are provided in the slider, so affix the load using these holes (indicated by arrows in the figure shown to the left). Type Slider mounting hole SA6C, SA7C M5, depth 9 mm Nominal thread size Tightening torque Bolt bearing surface: steel...
  • Page 43 Rod Type A bolt is attached on the rod end bracket, so use this bolt to affix the load. (Use the supplied nut, if necessary.) Rod end bracket Model Rod end bracket RA6C M8, length 18 mm RA7C M10, length 21 mm Note) Apply a spanner wrench at the rod end bracket to prevent the rod from receiving any rotating moment...

  • Page 44: Electrical Specifications

    Electrical Specifications Controller Specification item Description Number of controlled axes 1 axis/unit Supply voltage 24 VDC 10% Supply current 2 A max. Control method Weak field-magnet vector control Position number specification, numerical specification, simple Positioning command numerical/position number specification Position number Maximum 64 points Position table data and parameters are saved in nonvolatile Backup memory...

  • Page 45: Input/Output Interfaces

    Input/Output Interfaces Connector pin No. Signal name Description RS485 serial communication Control power, 24 V Brake release (The brake is released when 24 V, 150 mA is supplied.) Motor drive power, 24 V Control power, 0 V Shield J.S.T. Mfg. Receptacle housing Pin contact...

  • Page 46: Extension Cable

    Shield Shielded wire Shielded wire (Note 1) Twisted pair Note 2 (Note 2) Ground (2) Network connection cable (Model number: CB-ERC2-CTL001) Wire: Manufacturer: J.S.T. Mfg. Manufacturer: AMP Plug housing: PALR-04VF X1 e-CON connector, 4-pin plug (green) Socket contact: SPAL-001T-P0.5 X4...

  • Page 47: Sio Converter (Optional)

    SIO Converter (Optional) Model number: RCB-TU-SIO-A (Vertical installation) RCB-TU-SIO-B (Horizontal installation) This unit is a RS232C-RS485 converter. When multiple controllers are linked together, you can use the SIO converter to perform movement operations and edit parameters for all axes at the same time by connecting a teaching pendant to the mini-DIN, 8-pin connector on the converter.
  • Page 48 [4] D-sub, 9-pin connector (RS232C) A connection port with the PLC’s communication module. You can also connect a PC here. For the communication cable, use a RS232C crossed cable as explained below. [5] Mini DIN, 8-pin connector (RS485) A connection port with the teaching pendant. For the communication cable, use the cable (with RS232C/RS485 converter) supplied with the PC software (RCM-101-MW).

  • Page 49: Wiring

    J.S.T. Power & I/O cable Mfg. cable Network connection ERC2-SE actuator J.S.T. Mfg. 24-VDC control power, motor power, brake signal, ground, shield Caution: Do not connect any device to the mini-DIN connector and D-sub connector at the same time. If a device is connected to these connectors at the same time, a communication...
  • Page 50 An example of serial communication connection, including an emergency stop circuit, is shown below. Emergency stop is actuated by means of cutting off the motor drive power. Teaching pendant SIO converter TP connector pushbutton ERC2-SE actuator Terminal block EMG reset pushbutton switch...

  • Page 51: Sio Communication Connection Using A Relay Terminal Block

    4.1.1 SIO Communication Connection Using a Relay Terminal Block Teaching pendant PC, PLC Fabricated by the customer) SIO converter Power & I/O cable Relay terminal block J.S.T. J.S.T. Actuator 1 Mfg. Mfg. Actuator 2 Actuator 3 One-pair shielded cable (Fabricated by the customer) Terminal resistor 1/2W, 220 Actuator 16...

  • Page 52: Sio Communication Connection Using A 4-Way Junction

    (Note 2) If the actuators use different power supplies, align 0 [V] on all power supplies. (Note 3) The gateway unit power must be the same as 0 V of the ERC2 control power. (Note 4) Connect the shielded wire of each axis to FG.

  • Page 53: Address Assignment

    4.1.3 Address Assignment If multiple axes are connected, a slave number must be assigned to each axis so that the host can recognize the corresponding actuator. Assign addresses in the setting screen of the teaching pendant or PC. Overview of operation on the PC [1] Open the main window [2] Click Setup (S) [3] Bring the cursor to Controller Setup (C)

  • Page 54: Configuration Using A Gateway Unit

    (Note 2) If the actuators use different power supplies, align 0 [V] on all power supplies. (Note 3) The gateway unit power must be the same as 0 V of the ERC2 control power. (Note 4) Connect the shielded wire of each axis to FG.

  • Page 55: Sio Communication Connection Using A 4-Way Junction

    (Note 2) If the actuators use different power supplies, align 0 [V] on all power supplies. (Note 3) The gateway unit power must be the same as 0 V of the ERC2 control power. (Note 4) Connect the shielded wire of each axis to FG.

  • Page 56: Connecting An Emergency Stop Circuit, Etc

    Yellow (Green) Shield *1 The wire colors for standard cables and robot cables are different. The colors in parentheses are for robot cables. (Note 1) The gateway unit power must be the same as 0 V of the ERC2 control power.

  • Page 57: Explanation Of Operating Functions

    Explanation of Operating Functions ERC2-SE actuators support two operation modes: [1] “position number specification mode” in which the actuator is operated by specifying position numbers, and [2] “numerical specification mode” in which the actuator is operated by directly specifying values relating to the intended operation.

  • Page 58: Description Of Position Table

    Description of Position Table Create a position table using the PC software or teaching pendant. Refer to the operation manual for the PC software or teaching pendant you are using. This section explains the position table by using the PC software screen as an example. (The displayed items are different on the teaching pendant.) Positioning Position...
  • Page 59 Increasing the speed and acceleration/deceleration changes the transferring mass significantly, and the actuator characteristics also vary from one model to another. Therefore, consult IAI’s Sales Engineering Section for the maximum limits that can be entered in your specific application.
  • Page 60 “Push & hold operation” The set value defines the maximum distance the actuator will push the work part in the push & hold mode upon reaching the target position. Consider the mechanical variations of the work part and set an appropriate positioning band so that positioning will not complete before the actuator contacts the work part.
  • Page 61 (9) Acceleration/deceleration This field is not used for this controller. mode The factory setting is “0.” (10) Incremental This setting defines whether to use the absolute mode or incremental mode. The factory setting is “0.” 0: Absolute mode 1: Incremental mode (11) Command mode This field is not used for this controller.

  • Page 62: Relationship Of Push Force At Standstill And Current-Limiting Value

    5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value When performing operation in the push & hold mode, enter the current-limiting value (%) in the push column of the position table. Determine the current-limiting value (%) from the push force to be applied to the work part at standstill. The graphs below illustrate the relationship of push force at standstill and current-limiting value for each actuator type: Slider type...
  • Page 63 Rod type (1) RA6C type (2) RA7C type Low-speed type Low-speed type (Lead: 3 mm) (Lead: 4 mm) Current-limiting value (%) Current-limiting value (%) Medium-speed type Medium-speed type (Lead: 6 mm) (Lead: 8 mm) Current-limiting value (%) Current-limiting value (%) High-speed type High-speed type (Lead: 12 mm)

  • Page 64: Data Set In The Numerical Specification Mode

    For details, refer to the Operation Manual for Gateway Unit and the Operation Manual for Serial Communication Protocol. Explanation of Functions The table below lists the key functions available on ERC2-SE actuators in the position number specification mode and the numerical specification mode, respectively.

  • Page 66: Control Signals And Control Data

    5.3.1 Control Signals and Control Data To operate the actuator via serial communication, the internal 16-bit memory (Modbus registers and statuses) of the controller must be written/read. The key signals and symbols used in these operations are explained below. For details, refer to the Operation Manual for Serial Communication Protocol. (1) Controller input signals (PLC Controller)
  • Page 67 (PLC Controller) Signal Register Signal name Description address position symbol Position number specification 043AH PC32 register POSR Specify a command position number using 043BH PC16 Address a 6-bit binary code. 043CH 0D03H Positioning operation will start when the 043DH positioning start signal bit CSTR is [POS 043EH changed to “1.”...
  • Page 68 (PLC Controller) Register Address Description PCMD Position Upper Sign data specification Lower Signed 32-bit integer (unit: 0.01 mm) Setting range: FFF0BBC1H to 000F423FH (-999999 to 999999) A negative value is indicated by a 2’s complement. Accordingly, the most significant bit becomes “1.” Positioning operation will start when the lower word (9901H) of this register is [Numerical rewritten.
  • Page 69 (PLC Controller) Register Address Description Current- limiting value during push & hold operation 16-bit integer (unit: %, setting range: 00H to FFH/ 0 to 100 %) (Note) [Numerical Movement will start when this register is rewritten. specification] CTLF Control flag This flag sets a bit pattern to specify operation settings.
  • Page 70 (2) Controller output signals (Controller PLC) Signal Register Signal name Description address position symbol Emergency stop An emergency stop is being actuated when 0100H EMGS status this bit is “1.” Safety speed The safety speed is enabled when this bit 0101H SFTY enabled...
  • Page 71 (Controller PLC) Signal Register Signal name Description address position symbol Zone status register Position zone If individual zone boundaries are set in the ZONS output position table, this bit will turn “1” when the Address 0147H PZONE 9013H current position enters the range specified by the boundaries.

  • Page 72: Timings After Power On

    5.3.2 Timings after Power On Follow the procedure below to turn on the power after confirming that the slider or rod is not contacting a mechanical end nor the load is contacting any peripheral equipment: [1] Cancel the emergency stop or turn on the motor drive power. [2] Supply the 24-VDC controller power.
  • Page 73 If the actuator cannot be moved by hand, one option is to change parameter No. 28 (Default direction of excited-phase signal detection). If you wish to change this parameter, consult IAI in advance. Controller ready (PWR) This signal indicates whether the controller can be controlled externally.

  • Page 74: Home Return Operation

    5.3.3 Home Return Operation This controller uses an incremental position detector (encoder), and will therefore lose its mechanical coordinates once the power is cut off. For this reason, home return must be performed to establish mechanical coordinates every time the power is turned on.
  • Page 75 Home return command (HOME) Home return operation will start upon detection of the “0” “1” edge of this signal bit. When home return is completed, the home return completion (HEND) signal will be output. The HOME signal can be input as many time as desired even after home return has been completed once. (Note) Even if home return is not performed after the power has been turned on, the actuator will automatically perform home return operation as part of the first positioning operation (CSTR signal).

  • Page 76: Positioning Operation

    5.3.4 Positioning Operation First, change the position complete (PEND) signal bit to “1” by turning on the 24-VDC power by referring to 5.3.2. Home return is not yet complete immediately after the power has been turned on. Accordingly, home return operation must be performed using the home return command (HOME) as explained in 5.3.3.
  • Page 77 Explanation of operation [1] When the servo becomes ready after the supply voltage has been turned on, the servo ready (SV) and position complete (PEND) bits will turn “1.” After confirming that PEND is “1,” specify position 1 and change the positioning start (CSTR) bit to “1.”...
  • Page 78 Positioning start (CSTR) Upon detecting the “0” “1” leading edge of this signal bit, the controller will read the target position number specified by a binary code consisting of six bits from PC1 to PC32 (in the position number specification register) and cause the actuator to move to the target position of the corresponding position data.
  • Page 79 Position complete (PEND) This signal indicates that the target position has been reached, and turns ON only when the following conditions are satisfied: [1] The servo ready (SV) bit is “1” AND [2] the current position has reached the positioning band before each target position OR [3] the actuator has not missed the work part during push &...

  • Page 80: Push & Hold Operation

    5.3.5 Push & Hold Operation Just like with an air cylinder, the end of the rod can be pressed against a work part and maintained in this condition. The push & hold operation is useful in clamping or press-fitting of work parts. (1) Basic operation As shown below, the actuator moves to the specified target position, after which it will move at the specified push speed to push the work part over a distance up to the specified positioning band.
  • Page 81 [1] Specification of push & hold mode Set a value (current-limiting value) “other than 0” in the “Push” field of the position table. To specify the push & hold mode numerically, set bit 0 of the control flag specification register CTLF to “1.” [2] Push speed Set a desired push speed in parameter No.
  • Page 82 (2) The work part is missed during push & hold operation If the actuator did not contact the work part after moving the specified positioning band (= the motor current does not reach the current-limiting value during push & hold operation), the position complete signal will not be output. However, the applicable completed position number will still be output.
  • Page 83 (4) The push direction is set incorrectly Exercise caution when setting the push direction, because if the direction is set incorrectly, the position will deviate by twice the positioning band, as shown below. Speed Intended operation Actual operation Travel Positioning band Positioning band Positioning band Actual position reached Target position...

  • Page 84: Pause

    5.3.6 Pause When the pause command (STP) bit is changed to “1” while the actuator is moving, the actuator will decelerate to a stop. Since the remaining travel is held, changing STP to “0” again will resume the movement to complete the remaining travel.

  • Page 85: Speed Change During Movement

    5.3.7 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. However, the position at which to implement each speed change must be set. Position 1 Position 2 Position 1 Position 2 Position 1 Position 2 Position 3...
  • Page 86 (Note) If a pause command is issued while home return is in progress, the movement command will be held if the actuator has not yet contacted the mechanical end. If the actuator has already contacted the mechanical end and reversed, home return will be performed again from the beginning. Alarm reset (RES) Alarms will be reset at the “0”...

  • Page 87: Operation At Different Acceleration And Deceleration

    5.3.8 Operation at Different Acceleration and Deceleration (1) When the actuator is used in the position number specification mode, acceleration and deceleration can be set differently in the position table. (2) Numerical specification mode Acceleration/deceleration data (set in the register 9906H) becomes effective when the data is received. To set a deceleration different from an acceleration, therefore, change the acceleration/deceleration data while the actuator is moving.

  • Page 88: Zone Signal

    5.3.9 Zone Signal This signal is output (the bit turns “1”) when the current actuator position is inside the specified zone. The zone signal can be used for the following purposes: [1] As an interlock signal to prevent contact with peripheral equipment [2] As a trigger signal for peripheral equipment to shorten the tact time [3] For determining if the actuator has missed the work part during push &...

  • Page 89: 5.3.10 Pitch Feed By Incremental Specification

    5.3.10 Pitch Feed by Incremental Specification A target position can be specified in the position table using an incremental travel. This function is useful in operation involving multiple positioning points set apart by an equal distance (constant pitch feed). (1) Operation example in the position number specification mode The following example explains how to perform positioning at a 50-mm pitch, starting from position No.
  • Page 90 Command position Position 1 Position 2 Start (CSTR) Position complete (PEND) Completed position Position 1 Position 2 Position 2 Moving (MOVE) Zone signal (PZONE) Speed Actuator movement Time Distance from home *T1: Set to T1 0 (ms) by considering the scan time of the host controller. [Explanation of operation] [1] Perform positioning operation to position 1 (100.00 mm).
  • Page 91 (2) Note on positioning operation If a start signal is input after selecting and inputting a position number by incremental specification while the actuator is performing positioning operation, the actuator will move to the position representing the initial position plus the incremental travel. (If the specified incremental travel is a negative value, the actuator will move to the position representing the initial position minus the specified travel.) Example) Inputting a start signal for position 2 while the actuator is moving to position 1 will cause the actuator to move to the position 40 mm from the home.
  • Page 92 (3) Note on push & hold operation If a start signal is input after selecting and inputting a position number (for push & hold operation) by incremental specification while the actuator is moving in the push & hold mode, the actuator will move by the incremental travel from where the start signal was input.

  • Page 93: 5.3.11 Power-Saving Mode At Standby Positions

    5.3.11 Power-Saving Mode at Standby Positions One general feature of pulse motors is that their holding current is greater than AC servo motors in a standstill state. Therefore, we provide a power-saving mode to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position.

  • Page 94: Parameter Settings

    Parameter Settings Parameter Table Parameters are classified into four types according to their content. Category: a: Parameter relating to the actuator stroke range b: Parameter relating to the actuator operating characteristics c: Parameter relating to the external interface d: Servo gain adjustment No.

  • Page 95: Detailed Explanation Of Parameters

    Detailed Explanation of Parameters If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power. 6.2.1 Parameters Relating to the Actuator Stroke Range Soft limit (No. 3/4 LIMM/LIML) 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.
  • Page 96 Home return offset (No.22 OFST) The controller is shipped from the factory with an optimal value set in parameter No. 22, so the distance from each mechanical end to the home becomes uniform. The minimum setting unit is “0.01 [mm].” The home return offset can be adjusted in the following conditions: [1] Want to align the actuator home and the system’s mechanical home after the actuator has been assembled into the system...

  • Page 97: Parameters Relating To The Actuator Operating Characteristics

    6.2.2 Parameters Relating to the Actuator Operating Characteristics Default speed (No.8 VCMD) The factory setting is the rated speed of the actuator. When a target position is set in an unregistered position table, the setting in this parameter will be used as the speed data for the applicable position number.
  • Page 98 Should an excitation detection error or abnormal operation occur when the servo is turned on for the first time after a power on, one remedial action that can be taken is to change the detection time set in parameter No. 29. If you wish to change this parameter, contact IAI beforehand. Safety speed (No.35 SAFV) This parameter defines the feed speed to be applied during manual operation.
  • Page 99 Default standstill mode (No.53 CTLF) This parameter defines the power-saving mode to be applied when the actuator stands by for a long time while the machine is operating; the actuator stands by for a long time after completing home return operation; or the actuator stands by for a long time after completing positioning operation in the numerical specification mode.
  • Page 100 Push speed (No.34 PSHV) This parameter defines the push speed to be applied after the actuator reaches the target position in push & hold operation. Before the shipment, this speed has been set to a default value appropriate for the characteristics of the actuator. Set an appropriate speed in parameter No.

  • Page 101: Parameters Relating To The External Interface

    6.2.3 Parameters Relating to the External Interface Output mode of position complete signal (No.39 FPIO) This parameter defines the status of position complete signal to be applied if the servo turns off or “position deviation” occurs while the actuator is standing still after completing positioning. The following two conditions can be considered: [1] The position has deviated, due to external force and while the servo was on, beyond the specified “positioning band.”...
  • Page 102 Silent interval multiplication factor (No.45 SIVM) It is applied to controllers of RS485 serial communication type. If specified, this parameter defines the multiplication factor to be applied to the silent interval time for delimiter judgment in the RTU mode. The default setting is the communication time corresponding to 3.5 characters in accordance with the Modbus specification.

  • Page 103: Servo Gain Adjustment

    In particular, custom types (having a longer ball screw lead or stroke than standard types) are more vulnerable to vibration and noise due to external conditions. In such a case, the following parameter settings must be changed. Contact IAI beforehand. Servo gain number (No.7 PLG0) Parameter No.
  • Page 104 Speed loop integral gain (No.32 VLPT) Parameter No. Unit Input range Default Set individually in accordance with the actuator 1 ~ 217270 characteristics. This parameter is used to determine the response of the speed control loop. Reducing the set value lowers the response to speed commands, meaning that the reactive force that generates in response to load change becomes smaller.

  • Page 105: Troubleshooting

    Review the events leading to the occurrence of problem, as well as the operating condition at the time of occurrence. Check the serial numbers of the actuator. Analyze the cause. Take action. Please check items a) through i) before contacting IAI.

  • Page 106: Alarm Level Classification

    Caution: Before resetting an alarm, always identify and remove the cause of the alarm. If the cause cannot be removed or the alarm still persists after removing the cause, contact IAI. If the same error occurs again after resetting the alarm, the problem that caused the alarm...

  • Page 107: Alarm Description And Cause/Action

    Alarm Description and Cause/Action (1) Operation-cancellation level alarms Code Error name Cause/Action Movement command Cause: A movement command was issued by numerical specification when the at servo off servo was off. Action: Issue a movement command after confirming that the servo is on (SRDY or PEND is “1”).
  • Page 108 Action: Check for abnormality in the assembly condition of mechanical parts. If the actuator is suspected to be the cause, please contact IAI. 0C1 Servo error This alarm indicates that after receiving a movement command the motor is unable to operate for two seconds or more before reaching the target position.
  • Page 109 [2] Defective internal part of the controller Action: [1] Lower the ambient temperature of the controller. If the action in [1] does not apply, contact IAI. 0CC Abnormal control This alarm indicates that the voltage of the 24-V input power supply is excessive supply voltage (24 V + 20%: 28.8 V or more).
  • Page 110 Increasing the value of parameter No. 29 (Excited-phase signal detection time) may be effective. If you wish to change the parameter setting, contact IAI beforehand. [4] Move the actuator away from the mechanical end, and then turn on the power again.
  • Page 111 (As a rough guideline, the nominal service life of the nonvolatile memory is 100,000 rewrites.) Action: If the alarm persists after reconnecting the power, contact IAI. 0F6 Timeout writing to This alarm indicates that a response was not received within the specified time nonvolatile memory after writing the nonvolatile memory.

  • Page 112: Messages Displayed During Operation Using The Teaching Pendant Or Pc Software

    Messages Displayed during Operation Using the Teaching Pendant or PC Software This section explains the warning messages that may be displayed during operation using the teaching pendant or PC software. Code Error name Cause/Action Invalid data An inappropriate value was entered in a parameter. (Example) 9601 was entered as the serial communication speed by mistake.
  • Page 113 These conditions do not occur in normal operation. Should they occur, record the entire error list before cutting off the power for use in the cause investigation. Also contact IAI. This message indicates that no controller address is recognized. 30C No connected axis Cause: [1] The controller is not operating properly.

  • Page 114: Specific Problems

    [2] Loosen the fixing bolts and check if the slider moves smoothly. If the slider moves smoothly, review the affixing method and bolt tightening condition. [3] If the slide resistance of the actuator itself is large, please contact IAI. Noise occurs during downward movements in a vertical application.
  • Page 115 Cause: The current-limiting value is lower than what is required in view of the loading mass and slide resistance. Action: The actuator may have to be replaced in some cases. Please contact IAI. The speed is slow during push & hold operation.

  • Page 116: Maintenance And Inspection

    Maintenance and Inspection Inspection Items and Schedule Perform maintenance and inspection per the schedule specified below. This schedule assumes eight hours of operation a day. Shorten the inspection intervals if the utilization is higher, such as when the actuator is operated continuously day and night. Visual inspection of Greasing Model...

  • Page 117: Internal Check (Slider Type)

    Internal Check (Slider Type) [1] With the SA6 and SA7, the screw cover and side covers can be removed using a hex wrench with 1.5 mm width across flats. The front and rear brackets are supporting the ball screw, so do not disassemble these brackets.

  • Page 118: Internal Cleaning (Slider Type)

    If a large amount of foreign object is contained in the grease, wipe off the dirty grease before applying new grease. Greasing the Guide (Slider Type) (1) Applicable grease IAI uses lithium grease No. 2. The following grease is applied to the guides prior to shipment: Idemitsu Kosan Daphne Eponex Grease No. 2 Equivalent grease products are available from other companies.
  • Page 119 (2) Greasing method Grease the guide by following the procedure below: [1] Apply grease between the slider and base, as shown to the left. Apply grease on the opposite side in the same manner. [2] Spread the grease evenly between the slider and base using a spatula, as shown to the left.

  • Page 120: Greasing The Ball Screw (Slider Type)

    * With the ERC2, the speed will vary depending on the load. Be careful not to grease the ball screw excessively.

  • Page 121: Greasing The Rod Slide Surface

    Greasing the Rod Slide Surface (1) Applicable grease The following grease is applied to the rod slide surface prior to shipment: Kyodo Yushi Multemp LRL3 Use lithium grease for maintenance. Note: Never use fluorine grease. If fluorine grease is mixed with lithium grease, the grease function will drop and it causes damage to the mechanism.

  • Page 122: Motor Replacement Procedure

    Motor Replacement Procedure Before replacing the motor, save the latest parameter and position data. Save the data by one of the following methods: Save the data to a file using the PC software. Prepare position/parameter tables and manually write the values. When a new motor has been installed, enter the parameter/position data to the controller.
  • Page 123 Installation [1] Place the coupling spacer in the coupling hub. [2] Insert the motor unit into the rear bracket while paying attention to the phase of the coupling hub with respect to the coupling spacer. (When inserting the motor unit, exercise due caution to prevent pinching of parts.) [3] Insert the coupling bolt into the fitting hole in the motor unit from over the rear bracket, and tighten the bolt using a wrench with 3 mm width across flats.

  • Page 124: Operation Examples

    Operation Examples Refer to the operation manuals specified below for operation examples using this product: Operation Manual for DeviceNet Gateway Unit Operation Manual for CC-Link Gateway Unit Operation Manual for Serial Communication Protocol...

  • Page 125: Appendix

    Appendix 10.1 External Dimensions 10.1.1 ERC2-SA6C 4-M5 Depth 10 (300) 9 32 0.02 Cable joint connector 2- 5 7 Reamed, Depth 10 S E : Stroke End Ma Moment Offset Datum Position Mechanical End Teaching Port 13.5 49.1 Stroke 50.9 118.5...

  • Page 126: Erc2-Sa7C

    10.1.2 ERC2-SA7C 4-M5 Depth 10 (300) 9 47 0.02 Cable joint connector S E : Stroke End 2- 5 7 Reamed, Depth 10 Mechanical End Ma Moment Offset Datum Position Teaching Port 10 49.8 Stroke 55.2 118.5 Home .E.*2 S-4.5 Drilled Hole,...

  • Page 127: Erc2-Ra6C

    10.1.3 ERC2-RA6C (300) Home M.E. Cable joint connector Stroke M.E. Mechanical End Teaching Port M8 1.25 Nut 3 types M8 1.25 PIO type SIO type Secure 18 31.7 at least *There is no Teaching 118.5 49.7 Port for SIO Type.

  • Page 128: Erc2-Ra7C

    10.1.4 ERC2-RA7C (300) Home M.E. Cable joint connector Stroke M.E. Mechanical End Teaching Port M10 1.5 Nut 3 types M10 1.5 PIO type SIO type Secure at least 118.5 *There is no Teaching Port for SIO Type. Appearance Figure for Brake-equipped Type *Brake-equipped type is longer in 43.5mm and...

  • Page 129: Erc2-Rgs6C

    10.1.5 ERC2-RGS6C Home M.E. 51.7 ST 58.3 6-M5 Mechanical End 23.7 ST 3.3 Stroke Guide Weight [kg] Weight of Guide Main Unit [kg] 10.1.6 ERC2-RGS7C Home M.E. ST 61 Mechanical End 6-M6 57.5 ST 3.5 12.5 Stroke Guide Weight [kg]...

  • Page 130: Erc2-Rgd6C

    10.1.7 ERC2-RGD6C 4-M5 8-M5 23.7 ST 3.3 Mechanical End Home M.E. 51.7 ST 58.3 Stroke Guide Weight [kg] Weight of Guide Main Unit [kg] 10.1.8 ERC2-RGD7C 4-M6 8-M6 57.5 ST 3.5 Home M.E. ST 61 Mechanical End Stroke Guide Weight [kg]...

  • Page 134: Parameter Records

    10.3 Parameter Records Recorded date: 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 ZONM Zone boundary 1+ ZONL Zone boundary 1– LIMM Soft limit+ LIML...

  • Page 135: Change History

    Change History Revision Date Description of Revision January 2011 Fifth edition Added “Before Use.” Changed “Safety Precautions” to “Safety Guide.” P. 9: Added 1.5.3, “The sound pressure level of this product does not exceed 70 dB.” P. 16: Moved “Prohibitions/Notes on Handling Cables” to after 1.9, “Wiring.” P.
  • Page 138 825 PhairojKijja Tower 12th Floor, Bangna-Trad RD., Bangna, Bangna, Bangkok 10260, Thailand TEL +66-2-361-4458 FAX +66-2-361-4456 The information contained in this document is subject to change without notice for purposes of product improvement. Copyright © 2015. Jun. IAI Corporation. All rights reserved. 15.06.000...

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