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IAI ERC3 Instruction Manual

Actuator with integrated controller
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ERC3
Actuator with Integrated Controller
Instruction Manual
Fourteenth Edition
IAI Corporation

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  • Page 1 ERC3 Actuator with Integrated Controller Instruction Manual Fourteenth Edition IAI Corporation...

  • Page 3: Please Read Before Use

    • This instruction manual is an original document dedicated for this product. • This product cannot be used in ways not shown in this instruction manual. IAI shall not be liable for any result whatsoever arising from the use of the product in any other way than what is noted in the manual.
  • Page 4 ME0297-14E...

  • Page 5: Table Of Contents

    Table of Contents Safety Guide ································································································ 1 Guideline for Control Method ············································································· 8 Precautions in Operation ·················································································· 9 International Standards Compliances ································································ 13 Names of the Parts ························································································ 14 Actuator Coordinate ······················································································· 24 Starting Procedures ······················································································· 25 Chapter 1 Specifications Check ·································································· 31 Product Check ·····························································································31 1.1.1 Parts ·····························································································31...
  • Page 6 List of PIO Signals ·································································· 120 3.3.3 Circuit Diagram ·············································································· 122 Power Line and Emergency Stop Circuit ······································ 122 PIO Converter to ERC3 ···························································· 125 PIO Circuit ············································································· 126 MEC Mode 1 (Operation with PLC) ································································ 132 3.4.1 Wiring Diagram (Connection of construction devices) ····························· 132 3.4.2...
  • Page 7 4.1.1 Basic Operation Methods ································································· 163 Positioner Mode 1 (PIO Operation of ERC3) ································· 163 Pulse Train Control Mode (Pulse Train Operation of ERC3) ·············· 164 Positioner Mode 2 (Extended Operation of ERC3) ·························· 165 MEC Mode 1 ·········································································· 166 MEC Mode 2 ··········································································...
  • Page 8 Operation in Pulse Train Control Mode (How to Operate Pulse Train Control Type) ·· 255 Guideline for PIO Pattern Selection and Supportive Functions ·········· 255 Guideline for Supportive Functions ············································· 255 Power Supply and Emergency Stop Release (CP, MP, EMG) ··········· 256 Brake Release BK ···································································...
  • Page 9 Procedure for Replacement and Tuning ······································· 399 Motor Replacement Process ········································································· 401 Chapter 9 External Dimensions ································································ 403 ERC3-SA5C ····························································································· 403 ERC3-SA7C ····························································································· 404 ERC3D, ERC3CR-SA5C Standard Type (Stainless Steel Sheet Type), Cleanroom Type ························································································ 405 ERC3D, ERC3CR-SA7C Standard Type (Stainless Steel Sheet Type), Cleanroom Type ························································································...
  • Page 10 10.3 Conformity to Safety Category ······································································ 417 System Configuration ······························································ 417 Wiring and setting of safety circuit ·············································· 418 Examples of safety circuits ························································ 420 TP adapter and Related Parts ···················································· 426 10.4 When Connecting Power Supply with + Grounding ············································ 428 10.5 Example of Basic Positioning Sequence (PIO Patterns 0 to 3 in PIO Converter) ······...

  • Page 11: Safety Guide

    Safety Guide “Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. Operation Description Description...
  • 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”...
  • Page 13 Operation Description Description Installation and (2) Cable Wiring Start ● Use our company’s genuine cables 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.
  • Page 14 Operation Description Description Installation and (4) Safety Measures 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.
  • 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. ●...
  • Page 16 Operation Description Description Maintenance ● When the work is carried out with 2 or more persons, make it clear who is to and Inspection be the “leader” and who to be the “follower(s)” and communicate well with each other to ensure the safety of the workers. ●...

  • Page 17: Alert Indication

    Alert Indication The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the instruction manual for each model. Level Degree of Danger and Damage Symbol This indicates an imminently hazardous situation which, if the Danger Danger product is not handled correctly, will result in death or serious injury.

  • Page 18: Guideline For Control Method

    Guideline for Control Method ERC3 has numerous operation patterns and options to meet many criteria for different applications. Check Chapter 4 Operation for more details. When Quick Teach is used with Con mode only Jog Operation is available. Codes in brackets are model codes...

  • Page 19: Precautions In Operation

    Precautions in Operation 1. It is set to “high output” when the machine is delivered from the factory. There is a limit in the duty for the high output setting. Even though the transportable weight and maximum speed decrease, an operation with the duty 100% becomes available if the high output setting is set invalid in the parameters.
  • Page 20 13. Do not connect Quick Teach while a tool is being connected to TP connector (8-pin mini DIN) on ERC3 side. Since the communication with Quick Teach cannot be established, ERC3 cannot receive the high-output invalid command and runs with the high-output setting condition, resulting in a generation of the voltage drop error due to the capacity drop of the power supply unit inside Quick Teach.
  • Page 21 17. When using Pulse Train Control type, pay close attention to the pulse frequency; so the frequency will no exceed the actuator specification. In the pulse train control, the acceleration/deceleration speed is also controlled by the change of the command pulse frequency from the host controller. Be careful not to exceed the maximum acceleration/deceleration speed of the actuator.
  • Page 22 19. Transference of PIO Signal between Controllers Please note the following when conducting transference of PIO signal between controllers. To certainly transfer the signal between controllers with different scan time, it is necessary to have longer scan time than the one longer than the other controller. To ensure to end the process safely, it is recommended to have the timer setting more than twice as long as the longer scan time at least.

  • Page 23: International Standards Compliances

    International Standards Compliances This product complies with the following overseas standard. RoHS3 Directive CE Marking To be scheduled  ME0297-14E...

  • Page 24: Names Of The Parts

    Names of the Parts 1. Main Body In this instruction manual, the right and left sides of the actuator is expressed in the way it is placed horizontally and is looked from the motor side as shown in the figure below. (1) Slider Standard Type (Screw Cover Type) Screw for motor unit attachment Slider...
  • Page 25 (3) Slider Cleanroom Type Screw for motor unit attachment Slider Motor Unit Stainless Steel Sheet Right Side Opposite Side Motor Side of the Motor Left Side Status Indicator LED (SV/ALM) Side Cover Teaching Port Front Cover Slider Cover External I/F Connector Air Vacuum Joint Type Air Tube SA5:φ6, SA7:φ8 (4) Rod Type...

  • Page 26: Motor Unit

    2. Motor Unit 1) Status Indicator LED (SV/ALM) 2) Teaching Port 3) External I/F Connector Status Indicator LED Following show the controller operation status:  : Illuminating × : OFF ☆ : Flashing Status of PIO Output Signal Operation status CON Mode Type MEC Mode Type (GN)
  • Page 27 The functions of CON mode type in ERC3 can be extended. See 4.2.3 Operation in Positioner Mode 2 for details. Also, if ERC3 is Simple Absolute Type, the absolute battery is to be attached to this PIO Converter, thus it is mandatory.
  • Page 28 This is the battery to retain the encoder information for Simple Absolute Type. Affix it with fabric hook-and-loop fastener on the side of PIO Converter. If ERC3 is Simple Absolute Type, it is necessary that PIO Converter is a type that is applicable for Simple Absolute Type.
  • Page 29 Status Indicator LED (SYS) Following show the controller operation status:  : Illuminating × : OFF ☆ : Flashing Status of PIO Output Signal MEC Mode CON Mode Type Type Operation status SV Output *ALM Output *EMGS Output *ALM Output (GN) (RD) (Servo ON)
  • Page 30 • Display while Mode 1 (Alarm Code) being selected [refer to Chapter 7 for Alarm Codes] The alarm code issued in ERC3 is displayed in the hexadecimal system with the LED 0 to 15 used as 1 word of bit 0 to 15.
  • Page 31 13) ERC3 Connector [Refer to 3.3.3 [2], 3.5.3 [2]] This is the connector for the relay cable to connect ERC3 and PIO Converter. 14) Absolute Battery Connector [Refer to Chapter 6] It is the connector to plug in the enclosed battery if applicable for Simple Absolute Type.
  • Page 32 (2) Quick Teach (Model: RCM-PST-**) You can operate ERC3 easily. Not only JOG operation and home-return operation, but also the settings and changes of stop positions (2 or 3 points), acceleration/deceleration, speed and try run (forward / backward / continuous operations) are available.
  • Page 33 ON (normally for 100ms) MAX. 2.5A – ERC3 Connector When operating ERC3 directly with Quick Teach, plug the SIO type power supply and I/O cable. When Quick Teach is used as the teaching pendant, plug the SIO communication cable.

  • Page 34: Actuator Coordinate

    Actuator Coordinate The coordinate system of ERC3 is as shown below. 0 defines the home position, and items in ( ) are for the home-reversed type (option). For MEC Mode, the home position is the origin point and positive side is the end point.

  • Page 35: Starting Procedures

    Starting Procedures 1. Positioner Mode 1 When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below. “PC” stated in this section means “RC PC software”. Check of Packed Items No →...

  • Page 36: Pulse Train Control Mode

    2. Pulse Train Control Mode This product allows positioning control by the pulse train. It is necessary to have the positioning control function able to output the pulse train on the host controller (PLC). When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below.
  • Page 37 3. Positioner Mode 2 When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below. “PC” stated in this section means “RC PC software”. Check of Packed Items No → Contact us or our distributor.
  • Page 38 4. MEC Mode 1 When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below. “PC” stated in this section means “MEC PC software”. Check of Packed Items No → Contact us or our distributor.
  • Page 39 Connect a teaching tool such as PC to PIO Converter Is the green [SV] turned ON ↓ content of alarm and have and turn the power ON. in the ERC3 and PIO an appropriate treatment. Converter Status Display LEDs? ↓ Yes Settings of Initial Setting, Target Position, etc.
  • Page 40 6. MEC Mode 3 When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below. “PC” stated in this section means “MEC PC software”. No → Check of Packed Items Contact us or our distributor.

  • Page 41: Chapter 1 Specifications Check

    Parts This product is comprised of the following parts if it is of standard configuration. If you find any fault in the contained model or any missing parts, contact us or our distributor. (1) ERC3 Main Body Part Name Model Remarks Refer to “How to read the model plate”,...

  • Page 42: Teaching Tool

    The teaching tool is necessary to perform setup operations such as position and parameter settings through teaching or other means. The teaching tools listed below are available for ERC3. However, the available teaching tools differ for MEC Mode Type and CON Mode Type. Prepare an appropriate one considering the controller type.

  • Page 43: How To Read The Model Plate

    1.1.4 How to read the model plate (1) ERC3 Main Body MODEL ERC3-SA5-I-42P-20-50-SE-S-CN-B Model SERIAL No. 000049893 MADE IN JAPAN Serial number (2) PIO Converter (Option) Model MODEL RCB-CV-NPM-2-AB SERIAL No. 000049894 MADE IN JAPAN Serial number (3) Quick Teach (Option) Model MODEL：RCM-PST-0...

  • Page 44: How To Read The Model

    1.1.5 How to read the model (1) ERC3 Main Body ERC3 – SA5 – I – 42P – 20 – 50 – SE – S – CN – B – ** Identification for IAI use only (Note 1) Series Name Standard Type <Option>...
  • Page 45 1 : Single-phase 100V AC (100V AC power supply type) 2 : Single-phase 100 to 230V AC (200V AC power supply type) Note 1 Identification for IAI use only : This may be marked for the purpose of IAI. It is not an ID to describe the model code.

  • Page 46: Specifications

    1.2 Specifications 1.2.1 Actuator [1] High Output Setting (1) Enabling/Disabling of High Output Setting This actuator can select whether to enable / disable the high output setting by the parameters. At the delivery, the high output setting is activated for all the controllers. Controller Type Parameter Setting...
  • Page 47 (2) Duty Ratio for High Output Setting When high output setting is enabled, duty is restrained respective to the surrounding temperature to control heat generation by the motor unit. For the actuators of slider type standard design (stainless sheet type), the duty ratio is different from that for the cleanroom type and other types.

  • Page 48: Maximum Speed

    [2] Maximum speed The maximum speed of the actuator is limited by the limit of the maximum ball screw revolution. The maximum speed in the actuators of slider type (screw cover type) is partly different from that in the stainless sheet type. (1) Slider Standard Type (Screw Cover Type) •...
  • Page 49 (2) Slider Standard Type (Stainless Steel Sheet Type), Slider Cleanroom Type • When high output setting is enabled Speed limits (Unit: mm/s) Maximum Speed Motor Lead Horizontal Minimum Stroke [mm] Size Type [mm] / Vertical Speed 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Horizontal 195 165 140 120 105 90 3.75...
  • Page 50 (3) Rod Type • When high output setting is enabled Speed limits (Unit: mm/s) Maximum Speed Motor Lead Horizontal / Minimum Size Stroke [mm] Type [mm] Vertical Speed Horizontal 3.75 Vertical Horizontal Vertical RA4C Horizontal Vertical Horizontal Vertical Horizontal Vertical Horizontal Vertical RA6C...

  • Page 51: Max. Acceleration, Payload Capacity

    [3] MAX. Acceleration, Payload Capacity If the payload capacity is smaller than as specified, the acceleration/deceleration can be raised beyond the applicable level. (1) Slider Type Standard Type (Screw Cover Type), Standard Type (Stainless Steel Sheet Type), Cleanroom Type • When high output setting is enabled Payload capacity by acceleration/deceleration [kg] Lead Horizontal /...
  • Page 52 Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] Horizontal – – – – – – – – – – – – – Vertical – – – – – –...
  • Page 53 Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] Horizontal – – – – – – – – – – – – – – – – – – – –...
  • Page 54 Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] 26.5 26.5 26.5 26.5 12.5 Horizontal – – – – – – – – – – – – – – –...
  • Page 55 • When high output setting is disabled Acceleration/ Lead Horizontal / Velocity Load capacity Type Motor Type Deceleration [mm] Vertical [mm/s] [kg] Horizontal Vertical Horizontal Vertical SA5C Horizontal Vertical Horizontal 1000 Vertical 1000 ME0297-14E...
  • Page 56 Acceleration/ Lead Horizontal / Velocity Load capacity Type Motor Type Deceleration [mm] Vertical [mm/s] [kg] Horizontal Vertical Horizontal Vertical SA7C Horizontal Vertical Horizontal Vertical Caution: Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings. Doing so may result in vibration, failure or shorter life. If any acceleration/deceleration equal to or greater than the rated acceleration/deceleration is set, a creep phenomenon or slipped coupling may occur.
  • Page 57 (2) Rod Type • When high output setting is enabled Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] Horizontal 19.5 – – – – – – – – –...
  • Page 58 Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] Horizontal 17.5 16.5 – – – – – – – – – – – – – – – Vertical – –...
  • Page 59 Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] Horizontal – – – – – – – – – – – – – Vertical – – 11.5 – – –...
  • Page 60 Payload capacity by acceleration/deceleration [kg] Lead Horizontal / Type Motor Type Velocity [mm] Vertical 0.1G 0.3G 0.5G 0.7G 1.0G [mm/s] Horizontal – – – – – – – – – – – Vertical – – – – – RA6C – –...
  • Page 61 • When high output setting is disabled Acceleration/ Lead Horizontal / Velocity Load capacity Type Motor Type Deceleration [mm] Vertical [mm/s] [kg] Horizontal Vertical Horizontal Vertical RA4C Horizontal Vertical Horizontal Vertical ME0297-14E...
  • Page 62 Acceleration/ Lead Horizontal / Velocity Load capacity Type Motor Type Deceleration [mm] Vertical [mm/s] [kg] Horizontal Vertical Horizontal 17.5 17.5 Vertical 17.5 RA6C Horizontal Vertical Horizontal Vertical Caution: Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings.

  • Page 63: Driving System • Position Detector

    [4] Driving System • Position Detector (1) Slider Type Standard Type (Screw Cover Type), Standard Type (Stainless Steel Sheet Type), Cleanroom Type Ball Screw Type No. of Encoder Type Motor Type Lead Pulses (Note 1) Type Diameter Accuracy SA5C Rolled φ10mm SA7C Rolled...

  • Page 64: Positioning Precision

    [5] Positioning Precision (1) Slider Type Standard Type (Screw Cover Type), Standard Type (Stainless Steel Sheet Type), Cleanroom Type Type Lead Item Performance Positioning repeatability ±0.02mm 3, 6, 12 Lost motion 0.1mm or less SA5C Positioning repeatability ±0.03mm Lost motion 0.1mm or less Positioning repeatability ±0.02mm...

  • Page 65: Current Limit Value And Pressing Force

    [6] Current Limit Value and Pressing Force (1) Slider Type Standard Type (Screw Cover Type), Standard Type (Stainless Steel Sheet Type), Cleanroom Type • SA5C Pressing Force [N] Current Limit Value [%] Ball Screw Lead [mm] SA5C Current Limit Values and Pressing Force Lead 3 Lead 3 Lead 3...
  • Page 66 • SA7C Pressing Force [N] Current Limit Value [%] Ball Screw Lead [mm] 239 358 478 179 239 Correlation diagram of Pressing Force and Current Limit Lead 4 Lead 8 Lead 16 Lead 24 Current Limit [%] Caution: (1) The relation of the current limit and the pressing force is a reference assuming when the speed is 20mm/s.
  • Page 67 (2) Rod Type • RA4C Pressing Force [N] Current Limit Value [%] Ball Screw Lead [mm] 106 159 264 317 370 106 132 159 185 RA4C Current Limit Values and Pressing Force Lead 3 Lead 6 Lead 6 Lead 6 Lead 12 Lead 12 Lead 12...
  • Page 68 • RA6C Pressing Force [N] Current Limit Value [%] Ball Screw Lead [mm] 312 469 625 781 937 1094 156 234 312 391 469 156 195 234 104 130 156 RA6C Current Limit Values and Pressing Force 1200 1000 Lead 4 Lead 4 Lead 4 Lead 8...
  • Page 69 [7] Option (1) With Brake (Model: B) This is a function that is necessary when the actuator is mounted in the vertical orientation. This prevents a drop of work piece or fixture attached on the actuator when the power or servo is turned OFF.

  • Page 70: Built-In Controller

    1.2.2 Built-in Controller [1] Basic Specifications Item Description Power-supply Voltage 24V DC ±10% Load Current High output setting is enabled (Set in delivery) : 3.5A (MAX. 4.2A) (including current consumption for control) High output setting is disabled : 2.2A Power Supply for Electromagnetic Brake 24V DC ±10% 0.15A (MAX.) (Note 1) (In the case of the actuator with a brake)

  • Page 71: I/O Specifications

    [2] I/O Specifications (1) PIO Interfaces Input section Output section Rated Load Input Voltage 24V DC ±10% 24V DC ±10% Voltage Input Current 5mA / 1 circuit MAX. current 50mA / 1 point ON voltage IN.DC18V ON/OFF voltage OFF voltage MAX.DC6V Residual Voltage 2V or less...
  • Page 72 Pulse Train Output Specification Equivalent to Line Driver 26C31 ERC3 Control Power Supply Connected to 0V line on 24V DC For the host positioning unit, use the line driver 26C31 or equivalent with pulse train output specification. Format of Pulse Refer to 4.3 [7]...

  • Page 73: Control Option

    1.2.3 Control Option [1] PIO Converter (Model: RCB-□□□) (1) Basic Specifications Item Description Number of Controlled Axes 1 axis Power-supply Voltage 24V DC ±10% Load current when actuator is High output setting is enabled (Set in delivery) : 4.3A (MAX.5.0A) connected (including current consumption for High output setting is disabled : 3.0A...
  • Page 74 (2) External Dimensions  For Incremental Type (Standard) Operation width of DIN-fixed finger 5mm ME0297-14E...
  • Page 75  For Simple Absolute Type (Option) (49) Operation width of DIN-fixed finger 5mm ME0297-14E...
  • Page 76 (3) PIO Input and Output Interface Input section Output section Rated Load Input Voltage 24V DC ±10% 24V DC ±10% Voltage Input Current 5mA / 1 circuit MAX. current 50mA / 1 point ON voltage IN.DC18V ON/OFF voltage OFF voltage MAX.DC6V Residual Voltage 2V or less...

  • Page 77: Quick Teach (Model: Rcm-Pst-□)

    [2] Quick Teach (Model: RCM-PST-□) (1) Basic Specifications RCM-PST-0 RCM-PST-1 RCM-PST-2 Item 24V DC power supply type Equipped with 100V AC power Equipped with 200V AC power (Main unit of teaching pendant) supply unit supply unit RCM-PS-2 RCM-PS-1 Power Supply Unit (Equipped with 2m cable with –...
  • Page 78 (2) External Dimensions  RCM-PST-0 32.5 26.1 21.6 ME0297-14E...
  • Page 79  RCM-PST-1/RCM-PST-2 32.5 68.9 64.4 ME0297-14E...
  • Page 80 ME0297-14E...

  • Page 81: Installation

    Chapter 2 Installation 2.1 Transportation [1] Handling of Actuator, PIO Converter and Quick Teach Unless otherwise specified, the actuators are wrapped individually when the product is shipped out. Also, PIO Converter and Quick Teach are packaged separately. (1) Handling the Packed Unit •...

  • Page 82: Handling Of Multi-Axes Type

    [2] Handling of Multi-Axes Type This is the case that this product is delivered with other actuators being combined. Multi-axes type will be delivered in a package with an outer case fixed to a wooden base. Sliders are fixed so they would not accidently move while in transportation. The end of the actuator is also fixed to avoid it swinging by external vibration.

  • Page 83: Installation And Storage Environment

    2.2 Installation and Storage Environment This product is capable for use in the environment of pollution degree 2 or equivalent. *1 Pollution Degree 2 : Environment that may cause non-conductive pollution or transient conductive pollution by frost (IEC60664-1) [1] Installation Environment In general, the installation environment should be one in which an operator can work without protective gear.

  • Page 84: Storage • Preservation Environment

    [2] Storage • Preservation Environment (1) Actuator The storage • preservation environment should be similar to the installation environment. In addition, make sure condensation will not occur when the actuator is to be stored or preserved for a long period of time. Unless specified, we do not include drying agents when shipping the actuator.

  • Page 85: How To Install

    2.3 How to Install 2.3.1 Posture of Actuator Attachment  : Possible △ : Daily inspection is mandatory × : Not possible Horizontal Vertical Sideway Ceiling Mount Type Installation Installation Installation Installation Slider Standard Type (Screw Cover Type)   ...
  • Page 86 Caution: 1. When the unit is installed vertically oriented, attempt to put the motor up unless there is a special reason. Putting the motor on the lower side would not cause a problem in an ordinary operation. However, it may rarely cause a problem, when it is not operated for a long period, depending on the surrounding environment (especially high temperature), caused by the grease being separated and the base oil flowing into the motor unit.

  • Page 87: Installation Of Slider Type

    2.3.2 Installation of Slider Type The installation for the screw cover type, is different from that for the stainless sheet type (cleanroom type). [Refer to [1] and [2] for the screw cover type. Refer to [3] and [4] for the stainless sheet type (cleanroom type).] [1] Attachment of Actuator Body (Standard Type (Screw Cover Type)) The attachment surface should be a machined surface or a flat surface that possesses an...
  • Page 88 Datum Surface Datum Surface Detail of ERC3-SA5C Datum Surface Datum Surface Datum Surface Detail of ERC3-SA7C Datum Surface (For reference) Shown below is the section of platform when attaching using the datum. R0.3以下 A Dimension for Actuator Type Reference [mm] SA5C, SA7C 1.5 to 4.5 or less...
  • Page 89 (2) Mounting Method 1 (When utilizing tapped holes) Follow the table below for the torque to tighten the attachment screws. Tightening Torque [N•m] Actuator Tapping In the case that steel is used for the In the case that aluminum is used Type Diameter bolt seating surface:...

  • Page 90: Load Attachment (Standard Type (Screw Cover Type)

    Direction of allowable overhang For the calculation of Ma and Mc moments, consider the position indicated with an arrow as the datum point. ERC3-SA5C ERC3-SA7C Caution: An operation beyond the allowable moment and overhang load length would not only generate abnormal noise and vibration, but also may shorten the life of actuator extremely.
  • Page 91 • There are tapped holes on the slider top for the load attachment. Also, there are two reamed holes. Utilize the reamed holes when repeatability in the attachment after detaching is required. Also, when a tuning of such accuracy as the perpendicularity is required, use only one of the reamed holes.

  • Page 92: Attachment Of Actuator Body

    [3] Attachment of Actuator Body (Standard Type (Stainless Steel Sheet Type), Cleanroom Type) The attachment surface should be a machined surface or a flat surface that possesses an equivalent accuracy, and the flatness should be 0.05mm or less. Also, the platform should have a structure stiff enough to install the unit so it would not generate vibration or other abnormality.
  • Page 93 10.0 Datum Surface Datum Surface 25.0 Detail of ERC3-SA5C Datum Surface 11.5 Datum Surface Datum Surface 35.5 Detail of ERC3-SA7C Datum Surface (For reference) Shown below is the section of platform when attaching using the datum. R0.3以下 A Dimension for...
  • Page 94 (2) Mounting Method 1 (When utilizing tapped holes) Follow the table below for the torque to tighten the attachment screws. Tightening Torque [N•m] Actuator Tapping In the case that steel is used for the In the case that aluminum is used Type Diameter bolt seating surface:...

  • Page 95: Load Attachment (Standard Type (Stainless Steel Sheet Type), Cleanroom Type)

    Direction of allowable overhang For the calculation of Ma and Mc moments, consider the position indicated with an arrow as the datum point. ERC3-SA5C ERC3-SA7C Caution: An operation beyond the allowable moment and overhang load length would not only generate abnormal noise and vibration, but also may shorten the life of actuator extremely.
  • Page 96 • There are tapped holes on the slider top for the load attachment. Also, there are two reamed holes. Utilize the reamed holes when repeatability in the attachment after detaching is required. Also, when a tuning of such accuracy as the perpendicularity is required, use only one of the reamed holes.

  • Page 97: Air Suction Of Slider Type (Cleanroom Type)

    2.3.3 Air Suction of Slider Type (Cleanroom Type) • Cleanroom type can have the performance to comply with Cleanroom Class 10 (0.1μm) by vacuuming the air at the two vacuum joints. The table below shows the reference of vacuum capacity at the maximum speed for each model. Have the pipe layout to make the vacuum performance at the two points get even.

  • Page 98: Installation Of Rod Type

    2.3.4 Installation of Rod Type [1] Installation of Actuator Type Unit There are two ways to install, one is to use the T-shaped slots on the frame and other to install vertically with using the flange surface. The installed surface should be a machined surface or a flat surface which possesses an equivalent accuracy to it, and the flatness should be 0.05mm at the maximum.
  • Page 99 • When Using Foot Brackets (Option) When installing the unit with using the foot brackets, use the T slots as for the direct installation and affix with hex socket head cap screws. Actuator Recommended Tightening Torque [N•m] Type attachment screw φ6.6 through RA4C 71 57 20 10...
  • Page 100 (2) Mounting Method 2 (Installation using flange surface) • Direct Installation ４-B Actuator Tightening Torque Type [N•m] RA4C M6, depth 12 RA6C M8, depth 16 11.5 Regarding attachment screws • Use of high-tension bolts meeting at least ISO-10.9 is recommended. •...
  • Page 101 • When Using Flange Bracket (Option) When installing the unit with using the flange bracket, use the tapped holes as for the direct installation and affix with hex socket head cap screws. Tightening Torque [N•m] Actuator Mounting If the platform to If the platform to Type Screw...
  • Page 102 Caution: • When installing on the flange, do not apply external force to the unit. It may cause an operation error or damage with the external force. External Force 外力 External Force • Even if external force is not applied, when the length of the unit is 386mm or more and the actuator is installed horizontally, apply a support as shown in the figure below.

  • Page 103: Load Attachment

    [2] Load Attachment Utilize the threaded part on the rod tip to attach the load. Screw in the load or use the enclosed nut. The enclosed nut can also be used as a stopper to stop from loosened after the load is screwed in.
  • Page 104 Caution: • Do not attempt to apply the radial load to the tip of the rod. An operation with the radial load being applied may cause an abnormal noise or vibration resulted in generation of an alarm. Also, it may shorten the actuator life extremely. Radial Load •...

  • Page 105: Noise Prevention And How To Attach Electrical Devices

    Do not share the ground wire with or connect to other equipment. Ground each controller. ERC3 possesses a built-in controller in the actuator body. The frame ground line for this controller is equipped in the PIO type power and I/O cable. Connect this to the ground terminal using a relay terminal block.
  • Page 106 (2) When controlling with using PIO converter PIO Converter Other Copper Wire : PIO Converter equipment Connect to a ground cable with diameter 1.6mm (AWG14: 2mm or more. Earth Terminal Grounding resistance at 100Ω or less Other Other PIO Converter equipment equipment Do not share the ground wire with or connect...
  • Page 107 2) RCM-PST-1 Connect it to a power socket with a grounding electrode. If socket is not with a grounding electrode, use a 3P-2P conversion adopter and plug into 2P power socket. Connect the ground line to a ground terminal near the socket. Otherwise, cut the cable and connect it using a terminal block in an electromagnetic control box.
  • Page 108 3) RCM-PST-2 Connect a 3P power socket plug and plug into a power socket with a ground electrode as conducted in 2), or connect to a 2P power socket and have the ground line connected to a ground terminal near the socket. Otherwise, make a connection using a terminal block inside an electromagnetic control box.

  • Page 109: Precautions Regarding Wiring Method

    [2] Precautions regarding wiring method 1) Wire is to be twisted for the power supply. 2) Separate the signal and encoder lines from the power supply and power lines. [3] Noise Sources and Elimination Surge absorber Carry out noise elimination measures for electrical devices on the same power path and in the same equipment.
  • Page 110 2) Quick Teach • RCM-PST-0 (24V DC power supply type) As shown in the figure on the right, Quick Teach can be hanged on a wall using the hook hole for wall mount on 1.8mm or more the back of it if a pan head screw is prepared on a wall. M3 Pan Head Screw Head diameter φ6 max.

  • Page 111: Wiring

    3.1.1 Wiring Diagram (Connection of construction devices) I/O type of the model code is NP or PN. Teaching Pendant (Please purchase separately) ERC3 Accessory Cable for ERC3 CB-ERC3P-PWBIO□□□ (Note 1) PC software Power Supply (Please purchase separately) PLC (Please prepare separately)

  • Page 112: Pio Pattern Select And Pio Signal

    PIO Pattern Select and PIO Signal [1] PIO Pattern (Control Pattern) Selection There are three ways of control methods for ERC3 controllers. Set the most suitable PIO pattern to Parameter No.25 “PIO Pattern Select”. Refer to 4.2.2 Operation in Positioner Mode 1 for the details of PIO patterns.

  • Page 113: Pio Patterns And Signal Assignment

    [2] PIO Patterns and Signal Assignment The signal assignment of cable by the PIO pattern is as shown below. Follow the following table to connect the external equipment (such as PLC). Parameter No.25 (PIO Pattern) Selection Category PIO Functions 3-point (solenoid 8-point type 16-point type valve) type...

  • Page 114: List Of Pio Signals

    [3] List of PIO Signals The table below lists the functions of PIO signals. Refer to the section shown in Relevant Sections for the details of the control of each signal. Signal Relevant Category Signal Name Function Description Abbreviation Sections Emergency Stop Input It shuts the motor power supply.

  • Page 115: Circuit Diagram

    Apply contact CR when having external cutoff of driving source. The motor drive power line MP that turns ON/OFF at CR is as load current for the as shown below. When ERC3 high output setting activated: 3.5A (4.2A max.) Load current ERC high output setting invalid: 2.0A in-rush 8.3A...

  • Page 116: Pio Circuit

    [2] PIO Circuit 1) PIO Pattern 0 ··············· 8-point Type 0V (NPN Type) 24V DC (NPN Type) 24V DC (PNP Type) 0V (PNP Type) ERC3 PL 2 BR 2 PEND Position Completion Command Position No.1 GY 2 RD 2 HEND Home Return Completion Command Position No.2...
  • Page 117 2) PIO Pattern 1 ··············· Solenoid Valve Type 0V (NPN Type) 24V DC (NPN Type) 24V DC (PNP Type) 0V (PNP Type) ERC3 PL 2 BR 2 Current Position No.0 Start Signal No.0 GY 2 RD 2 Current Position No.1 Start Signal No.1...
  • Page 118 3) PIO Pattern 2 ··············· 16-point Type 0V (NPN Type) 24V DC (NPN Type) 24V DC (PNP Type) 0V (PNP Type) ERC3 PL 2 BR 2 PEND Position Completion Command Position No.1 GY 2 RD 2 HEND Home Return Completion Command Position No.2...

  • Page 119: Pulse Train Control Mode

    I/O type of the model code is PLN or PLP. Teaching Pendant (Please purchase separately) ERC3 PC software (Please purchase separately) Accessory Cable for ERC3 CB-ERC3P-PWBIO□□□ (Note 1) PLC (Please prepare separately) Power Supply A positioning unit of pulse train output type 24V DC is required.

  • Page 120: Pio Pattern Selection And Pio Signal

    3.2.2 PIO Pattern Selection and PIO Signal [1] PIO Pattern (Control Pattern) Selection There are two types of control method for the pulse train control. Set an appropriate PIO pattern suited to the use to Parameter No.25 “PIO Pattern Select”. Refer to 4.3 Operation in Pulse Train Control Mode for the details of PIO patterns.

  • Page 121: List Of Pio Signals

    [3] List of PIO Signals The table below lists the functions of PIO signals. Refer to the section shown in Relevant Sections for the details of the control of each signal. Signal Relevant Category Signal Name Function Description Abbreviation Sections Emergency Stop Input It shuts the motor power supply.

  • Page 122: Circuit Diagram

    Brake forcible release ERC3 2nd unit (Note 1) OR 1 MP_GND CP_GND RD 1 ERC3 3th unit or later (Note 1) OR 1 MP_GND CP_GND RD 1 Note 1 The load current for the emergency stop signal EMG to turn ON/OFF at contact CR is 24V DC and 10mA.

  • Page 123: Command Pulse Train Circuit

    Line Driver: 26C31 or equiv. To 0V of power supply in common with ERC3 control circuit (0V of 24V DC power supply) (2) When Host Unit is Open Collector System AK-04 (please purchase separately) is required for pulse train input.

  • Page 124: Pio Circuit

    [3] PIO Circuit (1) PIO Pattern 0 ·············· Positioning mode 0V (NPN Type) 24V DC (NPN Type) 24V DC (PNP Type) 0V (PNP Type) ERC3 PL 2 BR 2 Servo ON Status Servo ON GY 2 RD 2 Position Complete...
  • Page 125 (2) PIO Pattern 1 ·············· Pressing mode 0V (NPN Type) 24V DC (NPN Type) 24V DC (PNP Type) 0V (PNP Type) ERC3 PL 2 BR 2 Servo ON Status Servo ON GY 2 Position Complete/ RD 2 INP/TLR Torque Limit Select...

  • Page 126: Positioner Mode 2 (Extension Type By Pio Converter)

    3.3 Positioner Mode 2 (Extension Type by PIO Converter) 3.3.1 Wiring Diagram (Connection of construction devices) The model code for I/O type of ERC3 is SE (SIO type). Teaching Pendant (Please purchase separately) (Please prepare separately) PC Software I/O Flat Cable (Please purchase separately) CB-PAC-PIO□□□...

  • Page 127: Pio Pattern Selection And Pio Signal

    PIO Pattern Selection and PIO Signal [1] PIO Pattern (Control Pattern) Selection PIO Converter can extend the positioner function of ERC3, and enables to have 6 types of control methods. Set the suitable PIO pattern to Parameter No.25 “PIO Pattern Select”.

  • Page 128: Pio Patterns And Signal Assignment

    [2] PIO Patterns and Signal Assignment The signal assignment of cable by the PIO pattern is as shown below. Follow the following table to connect the external equipment (such as PLC). Parameter No.25 (PIO Pattern) Selection Category PIO Functions Positioning mode Teaching mode 256-point mode Number of positioning...
  • Page 129 Parameter No.25 (PIO Pattern) Selection Category PIO Functions Solenoid valve Solenoid valve 512-point mode mode 1 mode 2 Number of positioning 512 points 7 points 3 points points Home return signal × Wire   Pin No. Color Input Jog signal ×...

  • Page 130: List Of Pio Signals

    [3] List of PIO Signals The table below lists the functions of PIO signals. The detail of each signal is provided in this chapter. Refer to the relevant sections shown in the list below. Signal Relevant Category Signal Name Function Description Abbreviation Sections PTP Strobe...
  • Page 131 Signal Relevant Category Signal Name Function Description Abbreviation Sections Turns ON in the positioning width range after actuator operation. The INP signal will turn OFF if the position deviation PEND/INP Position Complete 4.2.3 [6], [7] exceeds the in-position range. PEND and INP can be switched over by the parameter.

  • Page 132: Circuit Diagram

    (Note 1) 2nd unit Nth unit PIO Converter 1st unit PIO Converter (Note 3) EMG (-) Emergency stop signal Drive cutoff relay ERC3 Motor power supply CP24V Control power supply EMG (-) PIO Converter 2nd unit CP24V EMG (-) PIO Converter...
  • Page 133 The motor driving power line MPI that is to be turned ON/OFF at contact CR2 and the load current of the emergency stop signal EMG(-) are follows; Load current ERC3 high output setting valid: 3.5A (MAX. 4.2A) ERC3 high output setting invalid: 2.0A During in-rush 8.3A...
  • Page 134 Pin Assignment on Power Supply Connector Power Supply Connector EMG(-) ME0297-14E...

  • Page 135: Pio Converter To Erc3

    [2] PIO Converter to ERC3 SIO type power supply and I/O cable PIO Converter ERC3 CB-ERC3S-PWBIO□□□ (Note 1) BGND CP_GND MP_GND Note 1 □□□ indicates the cable length. (Example) 030 = 3m ME0297-14E...

  • Page 136: Pio Circuit

    [3] PIO Circuit 1) PIO Pattern 0 ··············· Positioning mode (Standard type) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter BR- 1 BR- 3 Completed Position No.1 RD- 1 RD- 3 Completed Position No.2 OR- 1 OR- 3 Completed Position No.4 YW- 1...
  • Page 137 2) PIO Pattern 1 ··············· Teaching mode (Teaching type) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter BR- 1 BR- 3 Completed Position No.1 RD- 3 RD- 1 Completed Position No.2 OR- 1 OR- 3 Completed Position No.4 YW- 1 YW- 3 Completed Position No.8...
  • Page 138 3) PIO Pattern 2 ··············· 256-point mode (Number of positioning points : 256-point type) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter BR- 1 BR- 3 Completed Position No.1 RD- 1 RD- 3 Completed Position No.2 OR- 1 OR- 3 Completed Position No.4...
  • Page 139 4) PIO Pattern 3 ··············· 512-point mode (Number of positioning points : 512-point type) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter BR- 1 BR- 3 Completed Position No.1 RD- 1 RD- 3 Completed Position No.2 OR- 1 OR- 3 Completed Position No.4...
  • Page 140 5) PIO Pattern 4 ················ Solenoid Valve Mode 1 (7-point type) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter BR- 1 BR- 3 Current Position No.0 RD- 1 RD- 3 Current Position No.1 OR- 1 OR- 3 Current Position No.2 YW- 1 YW- 3...
  • Page 141 6) PIO Pattern 5 ················ Solenoid Valve Mode 2 (3-point type) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter PIO Connector Limit Switch Output BR- 1 BR- 3 Backward End Detection RD- 1 RD- 3 Forward End Detection OR- 1 OR- 3 Intermediate Position Detection...

  • Page 142: Mec Mode 1 (Operation With Plc)

    またはティーチングボックス (Please purchase separately) ( 注 1) ( オプション ) ERC3 パソコン対応ソフト PERSONAL COMPUTER (注1) (オプション) Accessory Cable for ERC3 CB-ERC3P-PWBIO□□□ (Note 2) MEC PC Software モータ電源 (Download from homepage) Power Supply 制御電源 (Please prepare separately) (注1) 24V DC...

  • Page 143: Pio Pattern Selection And Pio Signal

    Air cylinder Stopping at end point and start point. Detection of start position 2 points You can specify the moving Detection of start position ERC3 Detection of end position (2-point speed and Detection of end position Move signal 1 Solenoid A positioning) acceleration/deceleration.

  • Page 144: Operation Patterns And Signal Assignments

    [2] Operation Patterns and Signal Assignments The signal assignment of cable by the operation pattern is as shown below. Follow the table below to connect external equipment (such as a PLC). Operation pattern Stopping at 2 points Stopping at 3 points Wire (2-point positioning) (3-point positioning)

  • Page 145: List Of Pio Signals

    [3] List of PIO Signals The table below lists the functions of PIO signals. Refer to Section 4.4 [6] and [7] for the details of the control for each signal. Function Stopping at 2 points Stopping at 3 points Signal Contents of (2-point positioning) (3-point positioning)

  • Page 146: Circuit Diagram

    Note 4 Apply contact CR when having external cutoff of driving source. The motor drive power line MP that turns ON/OFF at CR is as load current for the as shown below. When ERC3 high output setting activated: 3.5A (4.2A max.) Load current ERC high output setting invalid: 2.0A During in-rush 8.3A...

  • Page 147: Pio Circuit

    1) Stopping at 2 points (2-point positioning) ······························· Movement by 1 input between 2 points (Single-solenoid mode) 0V (NPN Type) 24V DC (NPN Type) 0V (PNP Type) 24V DC (PNP Type) ERC3 Start point detection/ PL 2 BR 2 LS0/PE0 Positioning to start point complete...
  • Page 148 Movement by 2 input between 2 points (Double-solenoid mode) Movement by 2 input between 3 points (3-point positioning) 0V (NPN Type) 24V DC (NPN Type) 24V DC (PNP Type) 0V (PNP Type) ERC3 Start point detection/ PL 2 BR 2 LS0/PE0 Positioning to start point complete...

  • Page 149: Mec Mode 2 (Operation Using Pio Converter)

    3.5 MEC Mode 2 (Operation Using PIO Converter) 3.5.1 Wiring Diagram (Connection of construction devices) The model code for I/O type of ERC3 is SIO type (model code: SE). CB-PST-SIO050 Cable (Optional for Quick Teach) Teaching Pendant Quick Teach (Note 1) (Note 2)

  • Page 150: Pio Pattern Selection And Pio Signal

    Description cylinder (Reference) You can move the actuator between 2 points using the same control you would normally use ERC3 Sensor with an air cylinder. You can set the positions of the Air cylinder Stopping at end point and start point.

  • Page 151: Operation Patterns And Signal Assignments

    [2] Operation Patterns and Signal Assignments The signal assignment of cable by the operation pattern is as shown below. Follow the following table to connect the external equipment (such as PLC). Operation pattern Stopping at 2 points Stopping at 3 points Wire (2-point positioning) (3-point positioning)

  • Page 152: List Of Pio Signals

    [3] List of PIO Signals The table below lists the functions of PIO signals. Refer to Section 4.4 [6] and [7] for the details of the control for each signal. Function Stopping at 2 points Stopping at 3 points Signal Contents of (2-point positioning) (3-point positioning)

  • Page 153: Circuit Diagram

    (Note 1) 2nd unit Nth unit PIO Converter 1st unit PIO Converter (Note 3) EMG (-) Emergency stop signal Drive cutoff relay ERC3 Motor power supply CP24V Control power supply EMG (-) PIO Converter 2nd unit CP24V EMG (-) EMG (-)
  • Page 154 The motor driving power line MPI that is to be turned ON/OFF at contact CR2 and the load current of the emergency stop signal EMG(-) are follows; Load current ERC3 high output setting valid: 3.5A (MAX. 4.2A) ERC high output setting invalid: 2.0A During in-rush 8.3A...
  • Page 155 Pin Assignment on Power Supply Connector Power Supply Connector EMG(-) ME0297-14E...

  • Page 156: Pio Converter To Erc3

    [2] PIO Converter to ERC3 SIO type power supply and I/O cable PIO Converter ERC3 CB-ERC3S-PWBIO□□□ (Note 1) BGND CP_GND MP_GND Note 1 □□□ indicates the cable length. (Example) 030 = 3m ME0297-14E...

  • Page 157: Pio Circuit

    [3] PIO Circuit 1) Stopping at 2 points (2-point positioning) ······························· Movement by 1 input between 2 points (Single-solenoid mode) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter PIO Connector Start point detection/ BR- 1 BR- 3 LS0/PE0 Positioning to start point complete RD- 1...
  • Page 158 2) Stopping at 3 points (3-point positioning) ······························· Movement by 2 input between 2 points (Double-solenoid mode) Movement by 2 input between 3 points (3-point positioning) 0V(NPN Type) 24V DC(NPN Type) 24V DC(PNP Type) 0V(PNP Type) PIO Converter PIO Connector Start point detection/ BR- 1 BR- 3...

  • Page 159: Mec Mode 3 (Solo Operation With Quick Teach)

    [1] RCM-PST-0 (24V DC power supply type) Power Supply 24V DC External emergency stop signal (always closed and open in emergency stop) Accessory Cable for ERC3 CB-ERC3S-PWBIO□□□ (Note 1) Quick Teach Note 1 □□□ indicates the cable length. (Example) 030 = 3m ME0297-14E...

  • Page 160: Rcm-Pst-1

    Power Supply 24V DC External emergency stop signal (always closed and open in emergency stop) Accessory Cable for ERC3 CB-ERC3S-PWBIO□□□ (Note 1) Connect it to a power socket with a grounding electrode. If socket is not with a grounding electrode, use a 3P-2P conversion adopter and plug into 2P power socket.

  • Page 161: Rcm-Pst-2

    [3] RCM-PST-2 External emergency stop signal (always closed and open in emergency stop) Accessory Cable for ERC3 CB-ERC3S-PWBIO□□□ Connect a 3P power socket plug and plug into a power socket with a ground electrode as conducted in [2], or connect to a 2P power socket and have the ground line connected to a ground terminal near the socket.

  • Page 162: Wiring Method

    3.7 Wiring Method 3.7.1 Wiring of Actuator Use a dedicated connection cable of IAI for connection. [1] PIO type power and I/O cable (Model : CB-ERC3P-PWBIO□□□) □□□ indicates the cable length L. (Example 030 = 3m), MAX. 10m Model code display V0.5-3 (J.S.T.

  • Page 163: Sio Type Power And I/O Cable (Model : Cb-Erc3S-Pwbio□□□)

    Signal Name Pin No. Pin No. Signal Name – BGND BGND CP_GND GND<CP> MP_GND GND<MP> ● Cable bending radius It is a robot cable, which can be used for moving parts. ERC3-XX r = 36mm or more PIO Converter ME0297-14E...

  • Page 164: Wiring Between Pio Converter And Quick Teach

    3.7.2 Wiring between PIO Converter and Quick Teach SIO communication cable (Model: CB-PST-SIO050) Cable length = 5m Model code display 8PIN MINI DIN Connector (Overmolded) Housing: PADP-14V-1-S (J.S.T. Mfg.) Contact: SPND-002T-C0.5 (J.S.T. Mfg.) Signal Name Pin No. Pin No. Signal Name 120Ω...

  • Page 165: Wiring Between Pio Converter And Host Controller (E.g. Plc)

    3.7.3 Wiring between PIO Converter and Host Controller (e.g. PLC) The connection of I/O for PIO Converter is to be conducted with the dedicated I/O cable. The cable length is shown in the model code of PIO Converter. Check the model code of PIO Converter.
  • Page 166 • Use dedicated cables of IAI indicated in this instruction manual. Contact us if you wish to have a change to the specifications of the dedicated cables.
  • Page 167 • Do not pull the cable with a strong force. • Pay attention not to concentrate the twisting force to one point on a cable. • Do not pinch, drop a heavy object onto or cut the cable. • When a cable is fastened to affix, make sure to have an appropriate force and do not tighten too much.
  • Page 168 Follow the instructions below when using a cable track. • If there is an indication to the cable for the space factor in a cable track, refer to the wiring instruction given by the supplier when storing the cable in the cable track. •...

  • Page 169: Wiring Of Pio Converter Power Line Connector

    3.7.4 Wiring of PIO Converter Power Line Connector The wires of the power supply and the emergency stop circuit are to be connected to the enclosed connector (plug). Strip the sheath of the applicable wires for 10mm and insert them to the connector.

  • Page 170: Pulse Converter: Ak-04 (Optional Accessory)

    10mm or more. 5) Make the wiring between the host controller (PLC, etc.) and AK-04 as short as possible. Long one is easy to pick the noise. Also make the wiring between AK-04 to ERC3 as short as possible.

  • Page 171: Teaching Port Connector Connection Of Erc3 Main Unit

    Teaching Port is for the connection of teaching tools (except for Quick Teach) only. Connect the connector of a teaching tool in the way the insertion mark comes to the bottom side. It is able to put in/take OFF the connector while ERC3 power is ON. Teaching Pendant Insert Mark Caution: Removing the teaching pendant while the power is ON causes a transient emergency stop.

  • Page 172: Connection Of Sio Connector Of Pio Converter

    Connect the connector of a teaching tool in the way the insertion mark comes to the left side. It is able to put in/take OFF the connector while ERC3 power of PIO Converter is ON. CB-PST-SIO050 (Optional casing for Quick Teach)

  • Page 173: Operation

    Chapter 4 Operation Basic Operation ERC3 has 6 types of operation method when combined with peripheral devices. In addition, each operation method has several operation patterns to meet various ways of use. Please note, though, that these patterns are to be determined by selecting the model code when in order, thus have an operation with a control logic that corresponds to the model code.

  • Page 174: Pulse Train Control Mode (Pulse Train Operation Of Erc3)

    Teaching Tool Set the pulse train format and the electric gear ratio (the distance of actuator movement in mm against 1 pulse) to the parameters in the ERC3 with using a teaching tool such as PC software. Send pulses based on the moving distance of the actuator to the ERC3 from the PLC (positioning unit).

  • Page 175: Positioner Mode 2 (Extended Operation Of Erc3)

    [3] Positioner Mode 2 (Extended Operation of ERC3) By using the optional PIO Converter, a selection from six types of operation patterns and 512 points at the maximum of positioning are available. Also, the unit can be applicable for Single Absolute Type.

  • Page 176: Mec Mode 1

    200.00 0.30 0.30 Table of controller ERC3 Teaching Tool Using a teaching tool such as the MEC PC software, select an operation pattern, and set the target position (coordinate values), speed and acceleration/deceleration data that suits to the selected pattern.

  • Page 177: Mec Mode 2

    End Point 200.00 200.00 0.30 0.30 Table of controller ERC3 PIO Converter Teaching Tool [6] MEC Mode 3 Independent operation is available with Quick Teach, and enables to have such operations as a test run of actuators. Enter a data including...

  • Page 178: Parameter Settings

    4.1.2 Parameter Settings Parameter data should be set to be suit to the system or application. Parameters are variables to be set to meet the use of the controller in the similar way as settings of the ringtone and silent mode of a cell phone and settings of clocks and calendars. (Example) Soft Stroke Limit : Set a proper operation range for definition of the stroke end,...

  • Page 179: Operation In Positioner Mode

    Operation in Positioner Mode 4.2.1 Set of Position Table [It is not necessary to set up for Pulse Train Control Mode. Refer to Section 4.4 [2] for MEC Mode.] The values in the position table can be set as shown below. The number of position will be displayed according the selected pattern.
  • Page 180 (3) If the carriage weight is extremely lighter than the rating carriage weight, acceleration/deceleration larger than their rating values to shorten the cycle time. Please contact IAI for the settings in such situation. Inform us of the weight, shape and mounting method of the work and the installation conditions of the actuator.
  • Page 181 Positioning width [mm] ····· In PIO Patterns 0 to 4 in Positioner Mode 1 (for ERC3 unit) and Positioner Mode 2 (when PIO Converter is used), the positioning complete signal is output when the remaining movement amount gets into the area that is set in them when positioning is conducted.
  • Page 182 11) Acceleration/deceleration mode ········ Select a proper acceleration/deceleration pattern depending on the load. Acceleration/ Operation Value Deceleration Pattern Velocity Trapezoid Time Velocity S-motion (Refer to Caution at S-shaped Motion) Time Set the S-motion rate with parameter No.56. Velocity First-Order Lag Filter Time Set the delay time constant with parameter No.55.
  • Page 183 13) Transported load ···· Register 4 types of load weights with using the teaching tool, and choose the number from the registered numbers (0 to 3) that is to be used. From the numbers (load weights) registered in this section, the smart tuning calculates the optimum speed and acceleration/deceleration.

  • Page 184: Operation In Positioner Mode 1

    4.2.2 Operation in Positioner Mode 1 In Positioner Mode 1, it is available to select 3 types of PIO patterns with the parameters. This PIO Pattern cannot be switched over after the system is finished to be established or during the actuator operation.

  • Page 185: Overview Of Major Functions

    [2] Overview of major Functions Major functions Description Number of positioning points Number of positioning points which can be set in the position table. Operation with the Position No. Normal operation started by turning the start signal ON after Input position No.

  • Page 186: Power Supply And Emergency Stop Release (Cp, Mp, Emg, Pend)

    [3] Power Supply and Emergency Stop Release (CP, MP, EMG, PEND) ································································ [Refer to 3.1.3 Circuit Diagram] 1) Supply the control power (CP, CP_GND), first. 2) Secondly, turn ON the motor power source (MP, MP_GND) and the emergency stop signal EMG at the same time.

  • Page 187: Brake Release Bk

    [4] Brake release BK ········································· [Refer to 3.1.3 Circuit Diagram] This is a signal to compulsorily release the brake of the actuator equipped with a brake. The brake in the actuator is a non-excitation operation type electromagnetic brake. In a normal operation, it automatically releases the brake with the servo ON and gets to the brake operating status with the servo OFF.

  • Page 188: Operation Ready And Auxiliary Signals

    [6] Operation Ready and Auxiliary Signals (1) Home Return (HOME, HEND, PEND) Input Output PIO signal HOME HEND PEND Pattern 0    Pattern 1 × (Note1) × × Pattern 2 × (Note1)    : Available, ×: Unavailable (Note 1) For Patterns 1 and 2, a home-return operation with HOME Signal cannot be performed.
  • Page 189 (2) Zone Signal and Position Zone Signal (ZONE1, PZONE) Output Model name PIO signal ZONE1 PZONE Pattern 0 ×  ERC3 Main Body Pattern 1 × × Pattern 2 (Note 1) (Note 1)    : Available, ×: Unavailable Note 1 ZONE1 and PZONE cannot be used both at the same time.
  • Page 190 II. Position zone signal PZONE Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 0.00 250.00 0.20 0.20 0.10 50.00 30.00 100.00 250.00 0.20 0.20 0.10...
  • Page 191 Input Output Model name PIO signal *ALM Pattern 0 ×  ERC3 Main Body Pattern 1   Pattern 2 ×   : Available, ×: Unavailable Alarm signal *ALM is set to ON in the normal status but turned OFF at the occurrence of an alarm at a level equal to or higher than the operation release level.

  • Page 192: Operations Of Pio Patterns 0 And 2

    [7] Operation with the Position No. Input = Operations of PIO Patterns 0 and 2 Described in this section is how to operate in PIO Pattern 0 and 2 of ERC3 unit. These patterns provide normal controller operation methods in which the ROBO cylinder is operated by turning the start signal ON after a position No.
  • Page 193  Control method First enter command position No. PC1 to PC* with binary data. Next turn start signal CSTR ON. Then the actuator starts acceleration depending on the data in the specified position table for positioning to the target position. At operation start, positioning complete signal PEND is turned OFF.
  • Page 194 Command position No. PC1 to PC* (PLC→Controller) ≥ Turned OFF by Start signal CSTR turning PEND OFF (PLC→Controller) Home return complete signal This signal will turn ON when HEND home return has been completed. (Controller→PLC) Target Position Positioning Completion Signal PEND Turned ON (Controller→PLC)

  • Page 195: Control Method

    (2) Speed change during the movement  Sample use 1) 2) 6) 7) Positioning complete width at position 2 Velocity Positioning Completion Signal Output Positioning Position 3 Completion input Signal Output Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported...
  • Page 196 (3) Pitch Feeding (relative movement = incremental feed)  Sample use 2) 3) Velocity Position 1 Coodinates value: 100 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode...
  • Page 197 Caution: (1) If the actuator reaches the software limit corresponding to the stroke end in the pitch feed operation, the actuator stops at the position and positioning complete signal PEND is turned ON. (2) Note that, in pitch feed just after pressing operation (to be in the pressing state), the start position is not the stop position at the completion of pressing but the coordinate value entered in “Position”...
  • Page 198 (4) Pressing operation  Sample use 1) 2) 4) 5) Positioning width 50 Press-fitting process Velocity Caulking process Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm]...
  • Page 199 Command position No. PC1 to PC* (PLC→Controller) T1≥6ms (Note 1) Turned OFF by Start signal CSTR turning PEND OFF (PLC→Controller) Positioning Completion Not turned ON for Signal miss-pressing PEND (Controller→PLC) Pressing Pressing Approach operation Operation of actuator operation completion Movement by Positioning by setting Stop of positioning...
  • Page 200 Judging completion of pressing operation The operation monitors the torque (current limit value) in percent in “Pressing” of the position table and turns pressing complete signal PEND ON when the load current satisfies the condition shown below during pressing. PEND is turned ON at satisfaction of the condition if the work is not stopped.
  • Page 201 (5) Tension Operation  Image diagram Position No.1 Position No.2 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 100.00 250.00 0.20 0.20 0.10 0.00 0.00...
  • Page 202 Caution: (1) The speed during tension operation is set in Parameter No.34. The pressing operation speed is 20mm/s. The speed for pulling operation is same as that for pressing operation. Do not set any value larger than the value in the list. If the speed setting in the position table is below this set value, pressing is performed with the set speed.
  • Page 203 (6) Multi-step pressing  Image diagram Position No.1 Position No.2 Position No.3 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 0.00 250.00 0.20 0.20 0.10...
  • Page 204 (7) Pause and Operation Interruption (*STP, PEND) Input Output Model name PIO signal *STP PEND ERC3 Main Body Pattern 0 and 2   : Available, ×: Unavailable Velocity 4) 5) Positioning Completion Signal Output  Control method Pause is possible during movement. The pause signal is an input signal always set to ON. So, it is normally used to remain ON.

  • Page 205: Pio Pattern 1

    Position No. Input Output ERC3 Main Body [Caution] • Speed change is not allowed during movement. • There is no home-return signal. The actuator automatically performs the home-return operation with the first start signal ST* after the power is turned ON, and then performs an operation regarding the data in the indicated position number.
  • Page 206 Turned OFF by turning PE* ON Start signal Turned ON after (PLC→Controller) entering into positioning width Current position No. zone (Controller→PLC) Target Position Caution: (1) If the ST* signal is turned ON for the position after completion of positioning, both the PE* signal remain ON (except the pitch feed operation).
  • Page 207 (2) Pitch Feeding (relative movement = incremental feed)  Sample use 2) 3) Velocity Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 100.00 250.00 0.20...
  • Page 208 Caution: (1) If ST* Signal is turned ON at the same position number to repeat pitch feeding after positioning is complete, PE* Signal turns OFF at the operation start like the positioning in (1), and then turns back ON once the positioning is complete. (2) If the actuator reaches the software limit (stroke end) in pitch feed, the actuator is decelerated to be stopped and current position No.
  • Page 209 (3) Pressing operation  Sample use 250mm/sec 3) 4) Positioning width 50 Press-fitting process Velocity Positioning Completion Caulking process Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode...
  • Page 210 Caution: (1) The speed during pressing operation is set in Parameter No.34. The pressing operation speed is 20mm/s. Do not set any value larger than the value in the list. If the speed setting in the position table is below this set value, pressing is performed with the set speed.
  • Page 211 Judging completion of pressing operation PIO converter monitors the torque (current limiting value) set in % in “Pressing” in the position table, and turns ON the pressing complete signal PE* when the load current reaches the following condition. PE* is turned ON at satisfaction of the condition if the work is not stopped. Accumulated time in which current reaches pressing value [%]) –...

  • Page 212: Control Method

    (4) Tension Operation  Image diagram Position No.1 Position No.2 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 100.00 250.00 0.20 0.20 0.10 0.00 0.00...
  • Page 213 Caution: (1) The speed during tension operation is set in Parameter No.34. The pressing operation speed is 20mm/s. The speed for pulling operation is same as that for pressing operation. Do not set any value larger than the value in the list. If the speed setting in the position table is below this set value, pressing is performed with the set speed.
  • Page 214 (5) Multi-step pressing  Image diagram Position No.1 Position No.2 Position No.3 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 0.00 250.00 0.20 0.20 0.10...
  • Page 215 (6) Pause and Operation Interruption (ST*, *STP, RES, PE*) Pause is possible during movement. In this mode, the following two methods are possible for pause. Use of pause signal *STP Turning reset signal RES ON during the pause allows the remaining moving distance to be cancelled to interrupt the operation.
  • Page 216 Caution: (1) At occurrence of an alarm in the release level Note 1 , RES can reset the alarm. Cancel the remaining moving distance after confirmation that alarm signal *ALM (being ON in normal state and OFF at occurrence of an alarm) is set to ON. (2) If *STP is turned OFF when the actuator is in a positioning complete condition, PE* would not turn OFF.

  • Page 217: Operation In Positioner Mode 2 (Operation Using Pio Converter)

    To perform an operation of Position Mode 2, PIO Converter (option) is necessary. By using PIO Converter, an operation with extended function of ERC3 is available. It is available to select 6 types of PIO patterns with the parameters. This PIO Pattern cannot be switched over after the system is finished to be established or during the actuator operation.

  • Page 218: Overview Of Major Functions

    [2] Overview of major Functions Major functions Description Number of positioning points Number of positioning points which can be set in the position table. Operation with the Position No. Normal operation started by turning the start signal ON after Input position No.

  • Page 219: Power Supply And Emergency Stop Release (Cp24, Mpi, Mpo, Emg(-))

    [3] Power Supply and Emergency Stop Release (CP24, MPI, MPO, EMG(-)) [Refer to 3.3.3 Circuit Diagram] (1) Built-in Drive Cutoff Relay Type (Model: RCB-CV-□□□) 1) Supply the power (CP24, GND), first. 2) Secondly, turn ON the motor power source and the emergency stop signal at the same time.

  • Page 220: Operation Ready And Auxiliary Signals

    [5] Operation Ready and Auxiliary Signals (1) Emergency stop status EMGS Output PIO signal *EMGS Common to Patterns  0 to 5  : Available, ×: Unavailable The emergency stop status EMGS is turned ON when in normal condition and turned OFF when EMG(-) terminal on “3.3.3 Circuit Diagram”...
  • Page 221 Servo Brake Excitation Lock Release 26ms PEND T (before detecting excitation) = SON signal identification (6ms) + Excitation detection time (T1 + T2) × Number of retry (10 times Max.) + Servo ON delay time (T3) T (after detecting excitation) = SON signal identification (6ms) + Servo ON delay time (T3) T1 : Parameter No.30 It differs depending on the setting of excitation detection type.
  • Page 222 (3) Home Return (HOME, HEND, PEND, MOVE) Input Output PIO signal HOME HEND PEND MOVE Patterns 0 to 1     Patterns 2 to 4 ×    Pattern 5 × × × (Note 1)   : Available, ×: Unavailable Note 1 Pattern 5 cannot make a home return with HOME signal.
  • Page 223 (4) Zone Signal and Position Zone Signal (ZONE1, ZONE2, PZONE) Output PIO signal ZONE1 ZONE2 PZONE (Note 2) (Note 2) Pattern 0    Pattern 1 ×  (Note 2)  Pattern 2 ×  (Note 2)  Pattern 3 (Note 1) ×...
  • Page 224 II. Position zone signal PZONE Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 0.00 250.00 0.20 0.20 0.10 50.00 30.00 100.00 250.00 0.20 0.20 0.10...
  • Page 225 (5) Alarm, Alarm Reset (*ALM, RES) Input Output PIO signal *ALM Common to Patterns   0 to 5  : Available, ×: Unavailable Alarm signal *ALM is set to ON in the normal status but turned OFF at the occurrence of an alarm (Note 1) at a level equal to or higher than the operation release level.
  • Page 226 (6) Binary Output of Alarm Data Output (*ALM, PM1 to 8) Output PIO signal *ALM PM1 to 8 Common to Patterns   0 to 3 Pattern 4 (Note 1) ×  Pattern 5 (Note 1) ×   : Available, ×: Unavailable (Note 1) Patterns 4 and 5 do not have this function.
  • Page 227 : ON : OFF ALM8 ALM4 ALM2 ALM1 *ALM Binary Code Description: Alarm code is shown in ( ). (PM8) (PM4) (PM2) (PM1) Actual speed excessive (0C0)      Overcurrent (0C8) Overvoltage (0C9) Overheat (0CA)   ...
  • Page 228 (7) Brake release BKRL Input PIO signal BKRL Pattern 0 ○ Pattern 1 (Note 1) × Patterns 2 to 5 ○  : Available, ×: Unavailable (Note 1) Pattern 1 does not have this feature The brake can be released while BKRL signal is set to ON. If a brake is installed in the actuator, the brake is automatically controlled by servo ON/OFF.

  • Page 229: Operations Of Pio Patterns 0 To 3

    [6] Operation with the Position No. Input = Operations of PIO Patterns 0 to 3 This is the operation method for PIO Patterns 0 to 3. This is a standard operation method when using PIO Converter that operates by turning the start signal ON after inputting the position number.
  • Page 230  Control method First enter command position No. PC1 to PC** with binary data. Next turn start signal CSTR ON. Then the actuator starts acceleration depending on the data in the specified position table for positioning to the target position. At operation start, positioning complete signal PEND is turned OFF.
  • Page 231  Binary data  : ON  : OFF Command position No. PC256 PC128 PC64 PC32 PC16 Completed position No. PM256 PM128 PM64 PM32 PM16                ...

  • Page 232: Control Method

    (2) Speed change during the movement  Sample use 1) 2) 6) 7) Positioning complete width at position 2 Velocity Positioning Completion Signal Output Positioning Completion Signal Output Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration...
  • Page 233 (3) Pitch Feeding (relative movement = incremental feed)  Sample use 2) 3) Velocity Position 1 Coodinate value: 100 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode...
  • Page 234 Caution: (1) If the actuator reaches the software limit corresponding to the stroke end in the pitch feed operation, the actuator stops at the position and positioning complete signal PEND is turned ON. (2) Note that, in pitch feed just after pressing operation (to be in the pressing state), the start position is not the stop position at the completion of pressing but the coordinate value entered in “Position”...
  • Page 235 (4) Pressing operation  Sample use 1) 2) 4) 5) Positioning width 50 Press-fitting process Velocity Caulking process Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm]...
  • Page 236 Command position No. PC1 to PC** (PLC→Controller) T1≥6ms (Note 1) Turned OFF by turning PEND OFF Start signal CSTR (PLC→Controller) Completed position PM1 to PM** PM1 to PM** = 0 (Note 2) PM1 to PM** = 0 (Note 2) (Controller→PLC) Not turned ON for Positioning completion signal miss-pressing...
  • Page 237 Caution: (1) The speed during pressing operation is set in Parameter No.34. The pressing operation speed is 20mm/s. Do not set any value larger than the value in the list. If the speed setting in the position table is below this set value, pressing is performed with the set speed.
  • Page 238 Judging completion of pressing operation The operation monitors the torque (current limit value) in percent in “Pressing” of the position table and turns pressing complete signal PEND ON when the load current satisfies the condition shown below during pressing. PEND is turned ON at satisfaction of the condition if the work is not stopped.
  • Page 239 (5) Tension Operation  Image diagram Position No.1 Position No.2 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 100.00 250.00 0.20 0.20 0.10 0.00 0.00...
  • Page 240 First define the positioning in position No.1. Next, the operation in position No.2 moves the actuator to the position of 80mm at the setting speed and rating torque and change to the tension operation. The actuator moves by 50mm in the negative direction in the tension operation.
  • Page 241 (6) Multi-step pressing  Image diagram Position No.1 Position No.2 Position No.3 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 0.00 250.00 0.20 0.20 0.10...
  • Page 242 (7) Teaching by PIO (MODE, MODES, PWRT, WEND, JISL, JOG+, JOG-) Input Output PIO signal MODE JISL JOG+ JOG- PWRT MODES WEND Other than × × × × × × × pattern 1 Pattern 1      ...
  • Page 243 Warning: (1) In home return incomplete state, software limit cannot stop the actuator. Take interlock and prohibit the operation or perform the operation carefully. (2) If the JISL signal is changed during inching operation, the inching being operated is continued. If JISL is changed during job operation, the jog is stopped.
  • Page 244 Caution: (1) Set the period taken from entering position No. to turning the PWRT ON to 6ms or longer. In spite of 6ms timer process in the PLC, commands may be input to the controller concurrently to cause writing to another position. Take the scanning time in the PLC into account, set a period as 2 to 4 times as the scanning time.
  • Page 245  Control method Pause is possible during movement. In addition, the remaining moving distance can be cancelled to interrupt the operation. The pause signal is an input signal always set to ON. So, it is normally used to remain ON. Use this function for interlock in case where an object is invaded into the moving direction of the actuator being moved.

  • Page 246: Direct Position Specification (Solenoid Valve Mode 1) = Operation Of Pio Pattern

    [7] Direct Position Specification (Solenoid Valve Mode 1) = Operation of PIO Pattern 4 The start signal is provided for every position number. Only turning ON the relevant input signal according to the table shown below allows the operation based on the data in the target position number to be performed.
  • Page 247  Control method When start signal ST* is turned ON, the actuator starts acceleration based on the data in the specified position table for positioning to the target position. For PIO converter, when the positioning is finished, the positioning complete signal PEND turns ON at the same time as Current Position No.
  • Page 248 (2) Pitch Feeding (relative movement = incremental feed)  Sample use 2) 3) Velocity Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 100.00 250.00 0.20...
  • Page 249 Caution: (1) Because pitch feed is repeated, turning ON the ST* signal of the same position after completion of positioning causes both the PE* and PEND signals to be turned OFF at operation start and turned ON again at completion of positioning in the same way as (1) Positioning.
  • Page 250 (3) Pressing operation  Sample use 250mm/sec 3) 4) Positioning width 50 Press-fitting process Velocity Positioning Completion Caulking process Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode...
  • Page 251 Turned OFF by turning PEND ON Start signal (PLC→Controller) Turned ON even Current position No. in miss-pressing (Controller→PLC) Not turned ON for Positioning completion signal miss-pressing PEND (Controller→PLC) Pressing Pressing Operation of actuator Approach operation Completion operation Movement by Stop of Positioning by setting positioning pressing...
  • Page 252 Judging completion of pressing operation The torque (current limit value) set in % in “Pressing” in the position table, and turns ON the pressing complete signal PEND when the load current reaches the following condition. PEND is turned ON at satisfaction of the condition if the work is not stopped. It is the same for PE*. (Accumulated time in which current reaches pressing value [%]) –...
  • Page 253 (4) Tension Operation  Image diagram Position No.1 Position No.2 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 100.00 250.00 0.20 0.20 0.10 0.00 0.00...
  • Page 254 First define the positioning in position No.1. Next, the operation in position No.2 moves the actuator to the position of 80mm at the setting speed and rating torque and change to the tension operation. The actuator moves by 50mm in the negative direction in the tension operation.
  • Page 255 (5) Multi-step pressing  Image diagram Position No.1 Position No.2 Position No.3 Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load mode [mm] mode 0.00 250.00 0.20 0.20 0.10...
  • Page 256 (6) Pause and Operation Interruption (ST*, *STP, RES, PE*, PEND) Pause is possible during movement. In this mode, the following two methods are possible for pause. Use of pause signal *STP Turning reset signal RES ON during the pause allows the remaining moving distance to be cancelled to interrupt the operation.
  • Page 257 Caution: (1) At occurrence of an alarm in the release level Note 1 , RES can reset the alarm. Cancel the remaining moving distance after confirmation that alarm signal *ALM (being ON in normal state and OFF at occurrence of an alarm) is set to ON. Note 1: [Refer to 4.4 Alarm List for details of alarms.] (2) Turning *STP OFF with the actuator being in the positioning complete state causes PE* and PEND to be turned OFF.

  • Page 258: Direct Position Specification (Solenoid Valve Mode 2) = Operations Of Pio Pattern 5 In Pio Converter

    [8] Direct Position Specification (Solenoid Valve Mode 2) = Operations of PIO Pattern 5 in PIO Converter The start signal is provided for every position number. By only turning ON the input signal corresponding to the 3-point positioning position, an operation becomes available with the data of the target position number.
  • Page 259 [Operation of Slider Type/Rod Type Actuator] Mechanical end Home With the ST0 signal being ON, the actuator moves toward the mechanical end at the home return speed. The movement speed is 20mm/s. The actuator is turned at the mechanical end and stopped at the home position. The moving distance is the value set by Parameter No.22 “Home return offset level”.
  • Page 260 (3) Positioning [Basic] (ST0 to ST2, LS0 to LS2) Position No. Input Output [Caution] Pressing and pitch feed are unavailable.  Sample use 200mm/s 100mm/s 2) 3) 5) 6) Velocity Accele- Decele- Thresh- Positioning Acceleration/ Position Velocity Pressing Zone+ Zone- Incre- Transported Stop...
  • Page 261 (Example) Repetition of ST1 → ST2 → ST1 → Insert timer Δt if necessary. Start signal Δt Δt (PLC→Controller) Δt Start signal (PLC→Controller) Position sensing output (Controller→PLC) Turned ON after Position sensing output entering into positioning width zone (Controller→PLC) Target Position Δt : Time required to certainly reach the target position after the position sensing output LS1 or 2 is turned ON.
  • Page 262 (4) Speed change during the movement  Sample use 2) 3) 4) 5) Positioning complete width at position 1 Velocity Accele- Decele- Thresh- Positioning Acceleration/ Position Velicoty Pressing Zone+ Zone- Incre- Transported Stop ration ration width Deceleration [mm] [mm/s] [mm] [mm] mental load...
  • Page 263 The timing chart shown below indicates that the actuator changes its speed while it moves to position No.1 after the completion of positioning at position No.2 and moves to position No.0. Start signal (PLC→Controller) Start signal (PLC→Controller) Start signal (PLC→Controller) Position sensing output (Controller→PLC) Position sensing output...
  • Page 264 (5) Pause and Operation Interruption (ST*, LS*) Turning start signal ST* OFF allows the actuator to be paused while it is moved. To restart it, turn the same ST* signal ON. Velocity Deceleration Movement and stop with restart with Start signal for Start signal for position 1 position 1...

  • Page 265: Operation In Pulse Train Control Mode (How To Operate Pulse Train Control Type)

    In Pulse Train Mode, the actuator can be operated by the pulse train output of the host controller (PLC) positioning control function. An operation in Pulse Train Control Mode is available when ERC3 is the pulse train control type (model code: PLN/PLP).

  • Page 266: Power Supply And Emergency Stop Release (Cp, Mp, Emg)

    [3] Power Supply and Emergency Stop Release (CP, MP, EMG) ······························································· [Refer to 3.2.3 Circuit Diagram] 1) Supply the control power (CP, CP_GND), first. 2) Secondly, turn ON the motor power source (MP, MP_GND) and the emergency stop signal EMG at the same time. Do not attempt to turn ON the emergency stop signal EMG prior to the motor power source.

  • Page 267: Time Constant For Control Signal Input

    [5] Time Constant for Control Signal Input The input signals of this controller incorporate an input time constant to prevent malfunction due to chattering, noise, etc. Make sure to input the signals continuously for 6ms or more. (Note) Command pulse train inputs (PP•/PP, NP•/NP) do not have input time constants. Also, it is necessary to input 16ms or more for CSTP Signal.
  • Page 268 Servo Brake Excitation Lock Release 26ms PEND T (before detecting excitation) = SON signal identification (6ms) + Excitation detection time (T1 + T2) × Number of retry (10 times Max.) + Servo ON delay time (T3) T (after detecting excitation) = SON signal identification (6ms) + Servo ON delay time (T3) T1 : Parameter No.30 It differs depending on the setting of excitation detection type.
  • Page 269 (2) Home Return (HOME, HEND) Input Output PIO signal HOME HEND The HOME signal is intended for automatic home return. When the HOME signal is turned ON, the command will be processed at the leading edge (ON edge) of the signal and the actuator will perform home return operation automatically. Once the home return is completed, the HEND (home return completion) signal will turn ON.
  • Page 270 (3) Alarm, Alarm Reset (*ALM, RES) Input Output PIO signal *ALM Alarm signal *ALM is set to ON in the normal status but turned OFF at the occurrence of an alarm (Note 1) at a level equal to or higher than the operation release level. Turning reset signal RES ON under occurrence of an alarm at the operation release level allows the alarm to be released.

  • Page 271: Pulse Train Input Operation

    [7] Pulse Train Input Operation (1) Command Pulse Input (PP•/PP, NP•/NP) In the differential type, it is able to have 200kpps of pulse train input at maximum. If the host controller is an open collector pulse output type, it is able to input the pulse of 60kpps at the maximum by connecting AK-04 (option).
  • Page 272 [Reference] Acceleration/deceleration settings of general positioning device Motor Rotation Velocity [mm/s] × 60 Motor Rotation [rpm] = Ball Screw • Lead Length [mm/rev] Time Constant 1G = 9800mm/s : Acceleration capable to accelerate up to 9800mm/s per second 0.3G : Acceleration capable to accelerate up to 9800mm/s × 0.3 = 2940mm/s per second Velocity 9800mm/s...
  • Page 273 (3) Torque Limit Select (TL, TLR) Input Output PIO signal INP→TLR (Note ) TLR is the function available only in Pattern 1. The torque limit signal TL is a signal that limits the torque for the motor. While this signal is ON, the actuator thrust can (motor torque) can be limited at the torque that was set in Parameter No.57 “Torque limit”.

  • Page 274: Settings Of Basic Parameters Required For Operation

    Electronic Gear Actuator Lead Length [mm/rev] Denominator (CDEN) Note 1 The encoder pulse of ERC3 is 800pulse/rev.  Formula for velocity: The velocity of the actuator can be figured out with the following formula. Velocity = Unit Travel Distance × Input Pulse Frequency [Hz]...
  • Page 275  Examples of electronic gear calculations: When operating ERC3 with 3mm lead length ball screw in 0.01 (1/100) mm of the movement per unit (Encoder pulse of ERC3 = 800pulse/rev) Electronic Gear Numerator (CNUM) No. of Encoder Pluses [pulse/rev] × Unit Travel Distance [deg/pulse]...
  • Page 276 (2) Format Settings of Command Pulse Train Set the command pulse train format in Parameter No.63 and active high/low in No.64. I. Command Pulse Mode User Parameter No.63 “Command Pulse Input Mode” Name Symbol Unit Input Range Initial Value Command Pulse CPMD –...

  • Page 277: Parameter Settings Required For Advanced Operations

    [9] Parameter Settings Required for Advanced Operations Depending on systems and/or loads, set the following parameters if necessary. (1) Position command primary filter time constant Input Initial Name Symbol Unit Range Value Position command primary 0.0 to PLPF msec filter time constant 100.0 The acceleration/deceleration of the actuator can be set in S-shaped curve with this parameter setting.
  • Page 278 (4) Error monitor during torque limiting Input Initial Name Symbol Unit Range Value Error monitor during torque limiting FSTP – 0 to 1 Selection can be made whether to enable/disable the motoring of the deviation during torque limiting (condition of TL signal being ON). If it is set enabled, error can be issued when the deviation exceeds the specified value while in torque limiting.

  • Page 279: Operation In Mec Mode 1 And 2 (Operation With Plc)

    Double Solenoid. ERC3 is controlled with PIO directly in MEC Mode 1 and via PIO Converter in MEC Mode 2, however, the operation method is the same for both modes. MEC Mode 2 is applicable for Simple Absolute Type.

  • Page 280: Positioning Complete Signal

    [2] Table for Operational Conditions (Position Table) and Positioning Complete Signal Approach Return Intermediate End point point Start point 2) 3) 4) 5) 1) to 6) = Parameter No.1 (Positioning width) ■ Operation Condition Table (Position Table) Used PIO (input and output) Signal Stop position Energy-...
  • Page 281 You can shorten the cycle time this way, so contact IAI if you are interested. When contacting IAI, let us know the weight, shape and installation method of the work part as well as installation condition of the actuator (horizontal/vertical).
  • Page 282 [Pushing toward the end point or intermediate point] Approach Speed Time Push width Start point Start position End point of push (intermediate point) [Pushing toward the start point or intermediate point = Pulling] Return Speed Time Push width Start point Start position End point (intermediate point)
  • Page 283 [Auto motor power (Auto servo) OFF] The motor power (servo) will turn off automatically upon elapse of a specified period after completion of positioning. When the next positioning command is issued, the motor power (servo) turns on automatically and positioning is performed. Since no holding current flows while the motor is at standstill, power consumption can be reduced.

  • Page 284: Power Supply And Emergency Stop Release

    [3] Power Supply and Emergency Stop Release (1) MEC Mode 1 (CP, MP, EMG) ···················· [Refer to 3.4.3 Circuit Diagram] 1) Supply the control power (CP, CP_GND), first. 2) Secondly, turn ON the motor power source (MP, MP_GND) and the emergency stop signal EMG at the same time.
  • Page 285 EMG or EMG(-) Servo Brake Lock Excitation Release 26ms T (before detecting excitation) = SON signal identification (6ms) + Excitation detection time (T1 + T2) × Number of retry (10 times Max.) + Servo ON delay time (T3) T (after detecting excitation) = SON signal identification (6ms) + Servo ON delay time (T3) T1 : Parameter No.36 It differs depending on the setting of excitation detection type.

  • Page 286: Brake Release Bk

    [4] Brake release BK········································· 3.4.3 Refer to Circuit Diagram] This is an input signal to compulsorily release the actuator brake with a function of MEC Mode 1. It is not equipped in MEC Mode 2. The brake compulsory release can be performed on the brake releasing switch mounted on the front panel of PIO Converter.

  • Page 287: Operation When Operation Pattern Is "2-Point Stop

    [6] Operation when Operation Pattern is “2-Point Stop (2-Point Positioning)” (1) Home Return (ST0, HEND, LS0, LS1, PE1) If the home-return operation is not performed with the operation panel, it will be performed with Movement Signal 1 to the first end point ST0. The actuator moves to the end point after home-return and then stops (for positioning).

  • Page 288: Operation When Operation Pattern Is "3-Point Stop

    (3) Pressing (ST0, PE0, PE1) The actuator performs the pressing operation towards the end point when Movement Signal 1 ST0 is ON. The end point positioning complete signal PE1 turns ON after the pressing is completed. When having a pressing (pulling) to the start point from the end position, turn OFF Movement Signal 1 ST0.

  • Page 289: Positioning)

    (2) Positioning Operation (ST0, ST1, LS0, LS1, LS2, PE0, PE1, PE2) Positioning is at the start point when Movement Signal 1 ST0 is ON, and at the end point when Movement Signal 2 ST1 is ON. When both ST0 and ST1 are ON , the positioning is at the intermediate point.
  • Page 290 (3) Pressing (ST0, ST1, PE0, PE1, PE2) Pressing movement to the end point is performed when Movement Signal 2 ST1 is ON. The end point positioning complete signal PE1 turns ON after the pressing is completed. Pressing towards the start point and intermediate point can be conducted by controlling Movement Signals 1 and 2 as the same as the ordinary positioning for the 3-point stop position (PE0 turns ON when pressing is complete at the start point and PE2 turns on when pressing is complete at the intermediate point).

  • Page 291: Operation In Mec Mode 3 (Test Run With Quick Teach.)

    0mm. changed or having a try run. make PIO commands of ERC3 valid. (Press it for 1 sec or more) STOP POS NUM Button TEACH MODE...

  • Page 292: Operations

    4.5.2 Operations [1] Switches Used for Mode Selection (Auto ⇔ Manual) When Switching to Press and hold MANUAL Button for 1 Manual Mode second or more and the mode changes to Manual Mode. (Auto → Manual) When the mode is changed, a peep sound is made and the manual lamp turns ON.

  • Page 293: Switch Used For Brake Release

    [5] Switch Used for Brake Release It is the brake compulsory release switch for the actuator equipped with a brake. Releasing Brake Slide the switch to the release side and the brake is compulsorily released. Have the operation of this switch on such occasions that a release of the brake is necessary as when a work piece is to be attached, the actuator needs to be moved...

  • Page 294: Switches Used For Position Teaching

    [7] Switches Used for Position Teaching The position (forward, backward and intermediate) can be registered with moving the actuator without using the teaching tool. There are 2 types in the position programming. 1) Direct Teaching 2) Jog Teaching The following operations cannot be performed unless the home return operation is completed. (1) When Registering Position with Direct Teaching Switching to Position Press TEACH MODE Button.
  • Page 295 Registering Middle Press MIDDLE POS Button to select. If the Position mode is switched over, the lamp on (If set to 3-point MIDDLE POS button turns ON. positioning) Press SAVE Button. If the registration is complete, a peep sound is made and the save lamp turns ON.
  • Page 296 Registering Back Press BACK POS (start point) Button to Position (Start Point) select. If the mode is switched over, the lamp on BACK POS button turns ON. Press SAVE Button. If the registration is complete, a peep sound is made and the save lamp turns ON.

  • Page 297: Speed Settings

    [8] Switches and Rotary Knobs Used in Acceleration/Deceleration and Speed Settings The speed to move and the acceleration/deceleration speed of the actuator to the forward, backward and intermediate positions can be determined. Registering Twist Accel Dial and adjust at the desired Acceleration/ position.

  • Page 298: Test Run With Operation Panel

    4.5.3 Test Run with Operation Panel Turn ON Power Power Lamp turns ON in green. In Case of Error If an error is issued, Alarm Lamp turns ON Issued in red. Check the alarm code either on the PC software or the touch panel teaching to have an appropriate counteraction.
  • Page 299 ● To Perform Manual Operation Confirm the Home-return lamp is blinking and the home-return operation is completed. Perform a home-return operation if the Home-return lamp is off and the home-return operation is not completed. Manual Operation (when 2-point positioning) Move forward Move backward The actuator moves forward till it reaches the The actuator moves backward till it...
  • Page 300 ● To Confirm Current Positioning Point Number. 2pnt Lamp should be illuminated when set to 3pnt Lamp should be illuminated when set to 2-point positioning. 3-point positioning. ● To Change Positioning Point Number. Press STOP POS NUM Button. Confirm a buzzer is made for 2 seconds and release the buttons. If the current setting is 2-point stop →...
  • Page 301 ● Register the position. Confirm the Home-return lamp is blinking and the home-return operation is completed. Perform a home-return operation if the Home-return lamp is off and the home-return operation is not completed. (1) When Registering Position with Direct Teaching Press MANUAL Button.
  • Page 302 When selecting forward position Press FWD POS Button. The forward position lamp turns ON. When selecting backward position The backward position When selecting middle position Press BACK POS Button. lamp turns ON. This operation cannot be conducted while “2-point stop” is selected. The middle position lamp Press MIDDLE POS Button.
  • Page 303 (2) When Registering Position with Jog and Inching Operations Press MANUAL Button. A peep sound is made and the manual lamp turns ON. Press TEACH MODE Button. The lamps for Accel & Speed and Position turn ON. Move the actuator to a position where it is desired to be registered with pressing either JOG+ or JOG- button.
  • Page 304 When selecting forward position Press FWD POS Button. The forward position lamp turns ON. When selecting backward position The backward position When selecting middle position Press BACK POS Button. lamp turns ON. This operation cannot be conducted while “2-point stop” is selected. The middle position lamp Press MIDDLE POS Button.
  • Page 305 ● Register the acceleration and speed. Confirm the Home-return lamp is blinking and the home-return operation is completed. Perform a home-return operation if the Home-return lamp is OFF and the home-return operation is not completed. Press TEACH MODE Button. The Accel & Speed lamp turns ON and the Position lamp turns OFF.
  • Page 306 (Note) In the case that Quick Search (PCM-PST-1 or PCM-PST-2) integrated (connected) with the power unit is used to activate ERC3, the high output setting becomes invalid automatically when the Quick Search is connected. Therefore, the unit may not operate under the specifications of when the high output setting is valid.

  • Page 307: Power-Saving Function (Automatic Servo-Off And Full Servo Functions)

    Chapter 5 Power-saving Function (Automatic Servo-off and Full Servo Functions) ERC3 actuator possesses the automatic servo OFF function and full servo function to reduce the power consumption while the actuator is stopped. When using the power saving function, read the explanation in this section narrowly to understand well so there is no trouble in safety and operation.
  • Page 308 Content of PEND Parameter No.39 signal PEND PM1 to PM** PE** Positioning Completion Signal In-position Signal (Note) SV of ERC3 Motor Unit flashes in green while the automatic servo is OFF. Status Display LED flashes in green when using PIO Converter. ME0297-14E...
  • Page 309 [For Parameter No.39 = 0] Positioning Automatic servo Positioning Operation of actuator Servo OFF operation OFF standby operation Servo Condition Completed Position No. PM1 to ** =0 PM1 to ** = Output PM1 to ** = 0 PM1 to ** = 0 Output (Current position (PE** = OFF) (PE** = ON)

  • Page 310: Pulse Train Control Mode

    5.2 Pulse Train Control Mode Power saving cannot be performed with the automatic servo OFF. Only the full servo control setting is available. In the full servo function, the power consumption can be reduced by having a servo control to save the current during a stop.

  • Page 311: Mec Mode 1, 2 And 3

    The time setting from positioning complete till servo-off is to be established in the parameter. (Note) SV of ERC3 Motor Unit flashes in green while the automatic servo is OFF. Status Display LED flashes in green when using PIO Converter.
  • Page 312 Caution: (1) Automatic Servo-off Function is not effective while in pressing operation. Do not use. It becomes effective at completion of positioning. In pressing, the function becomes effective only when miss-pressing occurs (the status at the completion of operation without pressing is the same as that at the completion of positioning). (2) No retaining torque is provided in automatic servo-off.

  • Page 313: Full Servo Function

    5.3.2 Full Servo Function Set “1” in Parameter No.11 when full servo function is to be conducted. In the full servo function, the power consumption can be reduced by having a servo control to save the current during a stop. (1) Setting of Power Saving Method Select whether to turn the servo ON or to have the full servo control in Parameter No.11.
  • Page 314 ME0297-14E...

  • Page 315: Chapter 6 Adjustment Of Operation

    Chapter 6 Adjustment of Operation 6.1 Absolute Reset and Absolute Battery 6.1.1 Absolute Reset PIO Converter is necessary for Simple Absolute Type. Simple Absolute Type retains the encoder position information in the battery backup. It is not necessary to perform the home-return operation every time the power is turned ON.
  • Page 316 For TB-02/TB-03 Connect the actuator with the PIO converter. [Refer to Chapters 3.] Connect the absolute battery (enclosed battery at initial startup and new battery when replaced) to the absolute battery connecting connector on the bottom of the PIO converter. [Refer to 6.1.1 [3].] Connect teaching pendant and turn the power ON to PIO Converter.
  • Page 317 For TB-01 Connect the actuator with the PIO converter. [Refer to Chapters 3.] Connect the absolute battery (enclosed battery at initial startup and new battery when replaced) to the absolute battery connecting connector on the bottom of the PIO converter. [Refer to 6.1.1 [3].] Connect teaching pendant and turn the power ON to PIO Converter.

  • Page 318: Absolute Reset Using Pio

    Absolute reset using PIO This feature is valid in Positioner Mode 2. Turn the reset signal RES from OFF to ON. (Processed with ON edge.) Check that the alarm signal *ALM is ON (Alarm (Note 1) is cancelled). If the cause of the alarm is not removed, an alarm will be present again (*ALM signal OFF). Check the condition including other alarm causes.
  • Page 319 [Absolute Reset Process] Emergency stop actuated or cancelled (Status of power supply to the motor drive source) Safety Circuit Condition Control Power Input (Note 1) Motor Power Input (Note 1) Alarm reset Alarm Signal *ALM Alarm Code Output (PM8 to PM1) ALM LED * Pause Signal Pause is canceled.

  • Page 320: Absolute Battery

    Absolute Battery In PIO Converter for Simple Absolute Type, there are a battery for Absolute Type and fabric hook-and-loop faster enclosed. Separate the fastener and attach each to side surface of PIO Converter and the battery for Absolute Type. Join the fastener attached on the absolute battery and that on PIO Converter to fix them together.
  • Page 321 (Example) From Monday to Friday ; charge for 8 hours per day, discharge for 16 hours, Saturday and Sunday ; use with discharge 1) Parameter Setting Value: if it is 3… Full charge amount ; 24 [h] × 3 [day] = 72 [h] Total charge amount ;...

  • Page 322: Replacement Of Absolute Battery

    Replacement of absolute battery When replacing the battery, leave the power to the PIO converter ON, remove the battery connector and replace with a new battery. [Removal] Pull the connector to remove the battery. [Attachment] Attach the fastener enclosed Plug in connector to in the new battery to the side absolute battery surface of the new battery.

  • Page 323: High Output Setting And Gain Scheduling Function

    6.2 High Output Setting and Gain Scheduling Function 6.2.1 High Output Setting High output setting is a function to increase the speed, acceleration/deceleration and transportable weight. (It is set effective at delivery.) [Refer to 1.2.1 Actuator.] Setting of enable and disable switches over between the parameters of “Velocity Loop Proportional Gain”...

  • Page 324: Setting In Mec Mode 1 To 3

    6.2.4 Setting in MEC Mode 1 to 3 Making the high output setting enable/disable is to be conducted in Parameter No.28. The high output setting is set enable at the delivery. With the setting of enable/disable for the high output setting, the parameters are switched over between “Velocity Loop Proportional Gain”...

  • Page 325: I/O Parameter

    Leave a memo if using the teaching pendant. For a quick data recovery after such works as investigation on malfunction and replacement of ERC3 and PIO converter, it is also recommended to back up or take a note on the parameter after the setting change.

  • Page 326: Positioner Mode 1, Positioner Mode 2 And Pulse Train Control Mode

    6.3.1 Positioner Mode 1, Positioner Mode 2 and Pulse Train Control Mode I/O Parameter List The categories in the table below indicate whether parameters should be set or not. There are five categories as follows: A : Check the settings before use. B : Use parameters of this category depending on their uses.
  • Page 327 I/O Parameter List (Continued) For Pulse Relevant Default factory Name Symbol Unit Input Range Positioner Positioner Train sections setting Mode 1 Mode 2 Mode This section 0: Level B Movement command type FPIO – [2] (19)   1: Edge Default movement direction for 0: Reverse In accordance with...
  • Page 328 I/O Parameter List (Continued) For Pulse Relevant Default factory Name Symbol Unit Input Range Positioner Positioner Train sections setting Mode 1 Mode 2 Mode This section 0: Enabled Chapter 4 B Deviation counter clear input FPIO –  1: Disabled 4.3 [9] (5) 0: Enabled Chapter 4...
  • Page 329 I/O Parameter List (Continued) For Pulse Relevant Default factory Name Symbol Unit Input Range Positioner Positioner Train sections setting Mode 1 Mode 2 Mode This section – Overload level ratio OLWL 50 to 100 [2] (62) Gain scheduling upper limit 144 B GSUL 0 to 1023...

  • Page 330: Detail Explanation Of Parameters

    Detail Explanation of Parameters Caution: To make the setting enable after a change is made to parameters, have either the software reset or power reboot. Zone 1+, Zone 1- (Parameter No.1, No.2) Zone 2+, Zone 2- (Parameter No.23, No.24) Name Symbol Unit Input Range...
  • Page 331 Soft limit +, Soft limit - (Parameter No.3, No.4) Name Symbol Unit Input Range Default factory setting -9999.99 to Actual stroke on + Soft limit + LIMM 9999.99 side -9999.99 to Soft limit - LIML Actual stroke on - side 9999.99 0.3mm (deg) is added to the outside of the effective actuator stroke for the setting at the delivery (since there would be an error at the end of effective stroke if set to 0).
  • Page 332 Press & hold stop judgment period (Parameter No.6) Name Symbol Unit Input Range Default factory setting Press & hold stop judgment PSWT msec 0 to 9999 period Judging completion of pressing operation (1) The operation monitors the torque (current limit value) in percent in “Pressing” of the position table and turns pressing complete signal PEND ON when the load current satisfies the condition shown below during pressing.
  • Page 333 Servo gain number (Parameter No.7) Name Symbol Unit Input Range Default factory setting In accordance with Servo gain number PLGO – 0 to 31 actuator The servo gain is also called position loop gain or position control system proportion gain. The parameter defines the response when a position control loop is used.
  • Page 334 Default positioning width (in-position width) (Parameter No.10) Name Symbol Unit Input Range Default factory setting Default positioning width 0.01 to 999.99 0.10 (Note 1) When a target position is set in an unregistered position table, the setting in this parameter is automatically written in the applicable position number.
  • Page 335 (12) SIO communication speed (Parameter No.16) Name Symbol Unit Input Range Default factory setting SIO communication speed BRSL 9600 to 230400 38400 Set the SIO baud rate for the startup. Set an appropriate value in accordance with the communication speed of the host. Communication speed can be set from 9600, 14400, 19200, 28800, 38400, 76800, 115200 or 230400bps.
  • Page 336 In case the there is a necessity of setting a value less than the initial setting, contact IAI. (16) Zone 2+, Zone 2- (Parameter No.23, No.24) [Refer to 6.3.1 [2] (1).]...
  • Page 337 (17) PIO pattern selection (Parameter No.25) Name Symbol Unit Input Range Default factory setting PIO pattern selection IOPN – 0 to 5 0 (Standard Type) Select the PIO operation pattern in Parameter No.25. For the details of PIO patterns, refer to 4.2 Operation in Positioner Mode. [For Positioner Mode 1] Value set in Type...
  • Page 338 [For Positioner Mode 2] Value set in Type parameter Mode Overview No.25 • Number of positioning points : 64 points Positioning mode • Position command : binary code (at the Pattern 0 (Standard type) • Zone signal output : 1 point delivery) •...
  • Page 339 (19) Movement command type (Parameter No.27) Name Symbol Unit Input Range Default factory setting 0 : Level Movement command type FPIO – 1 : Edge This is the parameter enable in the operation modes and PIO patterns shown in the table below. It is able to change the start signals ST0 to ST* from level to edge treatment.
  • Page 340 (when compared in IAI products). There is a risk that the slider or rod may drop at the excitation phase signal detection if setting to “2”...
  • Page 341 (23) Velocity loop proportional gain (Parameter No.31) Name Symbol Unit Input Range Default factory setting Velocity loop proportional In accordance with VLPG – 1 to 27661 gain actuator This becomes enable when the setting of Gain Scheduling (Parameter No.144) and the high output setting (Parameter No.152) are set disable.
  • Page 342 (25) Torque filter time constant (Parameter No.33) Name Symbol Unit Input Range Default factory setting In accordance with Torque filter time constant TRQF – 0 to 2500 actuator This parameter decides the filter time constant for the torque command. When vibrations and/or noises occur due to mechanical resonance during operation, this parameter may be able to suppress the mechanical resonance.
  • Page 343 (28) Auto servo motor OFF delay time 1, 2, 3 (Parameter No.36, No.37, No.38) Name Symbol Unit Input Range Default factory setting Auto servo motor OFF delay ASO1 0 to 9999 time 1 Auto servo motor OFF delay ASO2 0 to 9999 time 2 Auto servo motor OFF delay ASO3...
  • Page 344 (31) Enable function (Parameter No.42) Name Symbol Unit Input Range Default factory setting 0 : Enabled Enable function FPIO – 1 : Disabled Set valid/invalid the deadman switch function if the teaching pendant is equipped with a deadman switch. Set Value Description Enable (Use the input signal) Disable (Does not use the input signal)
  • Page 345 (35) PIO inch distance, PIO inch distance 2 (Parameter No.48, No.49) Name Symbol Unit Input Range Default factory setting PIO inch distance IOID 0.01 to 1.00 (Note1) PIO inch distance 2 IOD2 0.01 to 1.00 Set the inching distance for the inching input command from PLC when PIO Pattern = 1 (Teaching Mode) is selected in Positioner Mode 2.
  • Page 346 (39) Default stop mode (Parameter No.53) Name Symbol Unit Input Range Default factory setting Default stop mode CTLF – 0 to 7 0 (Does not use) This parameter defines the power-saving function. [Refer to Chapter 5 Power-saving Function.] (40) Position-command primary filter time constant (Parameter No.55) Name Symbol Unit...
  • Page 347 (41) S-motion rate (Parameter No.56) Name Symbol Unit Input Range Default factory setting S-motion rate SCRV 0 to 100 This parameter is used when the value in the “Acceleration/deceleration mode” field of the position table is set to “1 [S-motion]”. This enables to ease the impact at acceleration and deceleration without making the takt time longer.
  • Page 348 (42) Torque limit (Parameter No.57) This parameter is exclusively used for the pulse-train control mode. [Refer to Chapter 4, 4.3 Operation in Pulse Train Control Mode, [9] Parameter Settings Required for Advanced Operations] (43) Deviation clear at servo OFF & alarm stop (Parameter No.58) This parameter is exclusively used for the pulse-train control mode.
  • Page 349 (51) Electronic gear denominator (Parameter No.66) This parameter is exclusively used for the pulse-train control mode.。 [Refer to Chapter 4, 4.3 Operation in Pulse Train Control Mode, [9] Parameter Settings Required for Advanced Operations] (52) Compulsory stop input (Parameter No.67) This parameter is exclusively used for the pulse-train control mode.。...
  • Page 350 (54) Ball screw lead length (Parameter No.77) Name Symbol Unit Input Range Default factory setting In accordance with Ball screw lead length LEAD 0.01 to 999.99 actuator This parameter set the ball screw lead length. The factory setting is the value in accordance with the actuator characteristics. Caution: If it is not suited to the actuator specifications, not only that operation cannot be performed with the indicated speed, acceleration/deceleration or movement amount, but also it may generate an alarm or cause malfunction.

  • Page 351: Stop Method At Servo Off (Parameter No.110)

    (57) Current limit value at stopping due to miss-pressing (Parameter No.91) Name Symbol Unit Input Range Default factory setting 0: Current limiting value at stop Current limit value at stopping PSFC – 1: Current limit due to miss-pressing value during pressing This parameter defines the restricted current value at stopping due to miss-pressing.
  • Page 352 (60) Monitoring mode (Parameter No.112) Name Symbol Unit Input Range Default factory setting 0: Does not use Monitoring mode FMNT – 1: Monitor function 1 2: Monitor function 2 The controller can be connected with PC software to monitor the servo. This parameter allows you to select a monitoring mode function (servo monitor).
  • Page 353 (63) Gain scheduling upper limit multiplying ratio (Parameter No.144) Name Symbol Unit Input Range Default factory setting Gain scheduling upper limit GSUL 0 to 1023 0 (Disabled) multiplying ratio Gain scheduling is the function to change the gain in accordance with the operation speed. This parameter shows the multiplying rate of the upper limit of the changeable gain.
  • Page 354 (67) Total operated distance threshold (Parameter No.148) Name Symbol Unit Input Range Default factory setting Total operated distance ODOT 0 to 999999999 0 (Disabled) threshold Notice will be made with Movement Distance Threshold Exceeding Alarm (04F) if the total distance of movement exceeds the value set in this parameter. The judgment would not be made if the value is set to 0.
  • Page 355 (70) BU velocity loop proportional gain (Parameter No.153) Name Symbol Unit Input Range Default factory setting BU velocity loop proportional BUPC – 1 to 10000 gain If the high output setting is set enabled, this parameter setting becomes enable for the velocity loop proportional gain.
  • Page 356 (72) Absolute battery retention time (Parameter No.155) Name Symbol Unit Input Range Default factory setting 0: 20 days Absolute battery retention 1: 15 days days time 2: 10 days 3: 5 days For Simple Absolute Type, establish the setting to define how long the position information of the encoder is to be remained for after the power to the controller is turned OFF.

  • Page 357: Servo Adjustment

    Take sufficient note on the setting. Record settings during servo adjustment so that prior settings can always be recovered. When a problem arises and the solution cannot be found, please contact IAI. Situation that requires How to Adjust adjustment Takes time to finish ●...
  • Page 358 Situation that requires How to Adjust adjustment Speed is uneven during ● Increase the value of “Velocity loop proportional gain”. By the movement setting a larger value, the follow-up ability to the speed command becomes better. Speed accuracy is not appropriate Setting too large value makes the mechanical components easy to vibrate.
  • Page 359 Situation that requires How to Adjust adjustment Large static friction of ● Set Parameter No.71 “Feed forward gain”. load makes actuator start Select a value in the range from 10 to 50 roughly. The larger the slowly. setting value is, the smaller the deviation is. Then the response Large load inertia makes is improved.

  • Page 360: Mec Mode 1, Mec Mode 2 And Mec Mode 3

    6.3.2 MEC Mode 1, MEC Mode 2 and MEC Mode 3 I/O Parameter List The categories in the table below indicate whether parameters should be set or not. There are five categories as follows: A : Check the settings before use. B : Use parameters of this category depending on their uses.
  • Page 361 Relevant Default factory For Mec For Mec For Mec Name Symbol Unit Input Range sections setting Mode 1 Mode 2 Mode 2 This section B Total movement count threshold TMCT time 0 to 99999999 0 (Disabled) [2] (20)   B Total operated distance threshold ODOT 0 to 99999999...

  • Page 362: Detail Explanation Of Parameters

    Detail Explanation of Parameters Default positioning width (in-position) (Parameter No.1) Name Symbol Unit Input Range Default factory setting Default positioning width 0.01 (Note 1) to 999.99 0.10 The positioning complete signal PEND/INP is output once the remaining movement amount comes into this width. Note 1 It is down to the minimum positioning width (L = Lead length/800).
  • Page 363 Velocity loop proportional gain (Parameter No.5) Name Symbol Unit Input Range Default factory setting Velocity loop proportional In accordance with VLPG – 1 to 27661 gain actuator It is enable when the high output setting (Parameter No.28) is set disable. This parameter determines the response of the speed control loop.
  • Page 364 Press velocity (Parameter No.7) Name Symbol Unit Input Range Default factory setting 0.01 to actuator's In accordance with Press velocity PSHV mm/s max. pressing actuator speed This is the parameter to set the velocity in pressing operation. If a change to the setting is required, make sure to have the setting below the maximum pressing velocity of the actuator.
  • Page 365 However, there is a risk that motor or controller may burn if the setting is too high. Please contact IAI. (12) Current-limiting value during home return (Parameter No.13)
  • Page 366 In case the there is a necessity of setting a value less than the initial setting, contact IAI. ME0297-14E...
  • Page 367 (15) Home return direction (Parameter No.17) Name Symbol Unit Input Range Default factory setting 0: Reverse In accordance with Home return direction – 1: Forward actuator Unless there is an indication of home-reversed type (option), the direction of the home return for the straight axis is located on the motor side.
  • Page 368 (18) Position Data Change Password (Parameter No.20) Name Symbol Unit Input Range Default factory setting Position Data Change PASS – 0000 to 9999 Password Set the password for when making a change to the position data. [Refer to MEC PC Software and teaching pendant instruction manuals provided separately for how to set up.] (19) PIO inch distance (Parameter No.25) Name...
  • Page 369 (23) BU velocity loop proportional gain (Parameter No.29) Name Symbol Unit Input Range Default factory setting BU velocity loop proportional BUPC – 1 to 10000 gain If the high output setting is set enabled, this parameter setting becomes enable for the velocity loop proportional gain.

  • Page 370: Servo Adjustment

    Take sufficient note on the setting. Record settings during servo adjustment so that prior settings can always be recovered. When a problem arises and the solution cannot be found, please contact IAI. Situation that requires How to Adjust adjustment Takes time to finish ●...
  • Page 371 Situation that requires How to Adjust adjustment Speed is uneven during ● Increase the value of Parameter No.3 “Velocity loop the movement proportional gain”. By setting a larger value, the follow-up ability to the speed command becomes better. Speed accuracy is not appropriate Setting too large value makes the mechanical components easy to vibrate.
  • Page 372 ME0297-14E...

  • Page 373: Troubleshooting

    Upon occurrence of a problem, take an appropriate action according to the procedure below in order to ensure quick recovery and prevent recurrence of the problem. 1) Status LEDs and PIO Check on ERC3 and PIO Converter [ERC3 main body] ...
  • Page 374 6) Check the connectors for disconnection or connection error. 7) Check the cables for connection error, disconnection or pinching. Cut off the main power of the system which ERC3 or PIO converter is installed in and remove the cables around the measurement point (to avoid conductivity through the surrounding circuit) before checking the conductivity.

  • Page 375: Fault Diagnosis

    Pulse Train Control Mode securely? Check the input signals 2) Positioner Mode 2. EMG on the ERC3 is not on the I/O monitor of the teaching SV in Status Display connected. tool such as PC software.
  • Page 376 [Refer to 7.4 Alarm List.] red at the power boot Pulse Train Control Mode (2) 1) Release the emergency stop in MEC Mode 1 or EMG on the ERC3 is not switch. MEC Mode 3. connected. 2) Positioner Mode 1, MEC Mode 1, 2) Positioner Mode 2.
  • Page 377 Situation Possible cause Check/Treatment Both position No. and There is a problem either in PIO signal 1) Is Status LED on ERC3 turned ON start signal are input to treatment, position table setting or in green? the controller, but the operation mode selection.
  • Page 378 [In the case of Pulse Train Control Mode] Situation Possible cause Check/Treatment In spite of inputting PIO signal processing or parameter 1) Is Status LED on ERC3 turned ON pulse-train to the setting is incorrect. in green? controller, the actuator 1) Servo OFF state If PIO Converter is used, is Status does not move.
  • Page 379 Emergency Stop Circuit.] the motor and control 2) Positioner Mode 2, MEC Mode 2 power are supplied to Check the connection of wires on ERC3 in MEC Mode1 PIO Converter power supply or MEC Mode3. connector EMG-. 2) Positioner Mode 2.

  • Page 380: Positioning And Speed Of Poor Precision (Incorrect Operation)

    No. after position No. command. Or complete the reading of the position No. command and start signal position numbers to ERC3 before are input concurrently. inputting the start signal. 2) The correct position No. is not [Refer to Chapter 4, 4.2 Operation specified due to PIO signal in Positioner Mode and 10.6...
  • Page 381 [In the case of Pulse Train Control Mode] Situation Possible cause Check/Treatment The actuator does not PIO signal processing or parameter 1) Check the setting of electronic gear stop at the command setting is incorrect. ratio. The host controller also has position.

  • Page 382: Generation Of Noise And/Or Vibration

    7.2.3 Generation of noise and/or vibration Situation Possible cause Check/Treatment Generation of noise Noise and vibration are generated by Servo adjustment may improve the and/or vibration from many causes including the status of load, situation. actuator itself the installation of the actuator, and the [Refer to 6.3.1 [3], 6.3.2 [3] Servo rigidity of the unit on which the actuator is Adjustment.]...

  • Page 383: Alarm Level

    Caution: Reset each alarm after identifying and removing the cause. If the cause of the alarm cannot be removed or when the alarm cannot be reset after removing the cause, please contact IAI. If the same error occurs again after resetting the alarm, it means that the cause of the alarm has not been removed.

  • Page 384: Alarm List

    7.4 Alarm List Positioner Mode 1 Alarm Alarm Pulse Positioner Alarm Name Cause/Treatment Code Level Train Mode 2 Mode 1 Mode 2 Control Mode Monitoring data Cause : Changing data type was directed type change during monitoring by the monitoring command during function of PC software.
  • Page 385 Positioner Mode 1 Alarm Alarm Pulse Positioner Alarm Name Cause/Treatment Code Level Train Mode 2 Mode 1 Mode 2 Control Mode Position Cause : A position move command was issued command in before home return was completed. incomplete Treatment : 1) Positioner Mode 1, Positioner Mode home return 2, Pulse Train Control Mode Issue a command after confirming...
  • Page 386 Positioner Mode 1 Alarm Alarm Pulse Positioner Alarm Name Cause/Treatment Code Level Train Mode 2 Mode 1 Mode 2 Control Mode Parameter data Cause : The data input range in the parameter error area is not appropriate. Example 1) This occurs when the relation of the positive and negative sides of the soft limit is clearly...
  • Page 387 Positioner Mode 1 Alarm Alarm Pulse Positioner Alarm Name Cause/Treatment Code Level Train Mode 2 Mode 1 Mode 2 Control Mode Command Cause : Because there is not enough deceleration deceleration distance when the error deceleration is changed to a lower setting during the operation, the actuator exceeded the soft limit when deceleration was made from the...
  • Page 388 Mode 1, if the problem is solved with 24V DC 150mA being supplied to BK, it may be concerned a malfunction of the controller inside the ERC3 motor unit. 3) Confirm that there is no error in the mechanical part assembly condition.
  • Page 389     concerned a degradation of motor winding insulation, malfunction of the controller inside the ERC3 motor unit, etc. Please contact IAI. Overvoltage Cause : The power voltage reached the overvoltage. Treatment : There may be concerned a ...
  • Page 390 Mode Overheat Cause : This shows the heat on the components inside the controller inside the ERC3 motor unit is too high. 1) Operation is performed with the load condition exceeding the specified range. 2) High temperature around the controller.
  • Page 391 Drive Source Cause : 1) Motor power input voltage (input to Error MP+ of ERC3) is too high for Position Mode 1, MEC Mode 1 and Pulse Train Control Mode Motor power input voltage (input to MPI of PIO Converter) is too high...
  • Page 392 Positioner Mode 1 Alarm Alarm Pulse Positioner Alarm Name Cause/Treatment Code Level Train Mode 2 Mode 1 Mode 2 Control Mode Deviation Cause : This alarm indicates that the position overflow deviation counter has overflowed. 1) The speed dropped or the actuator stopped due to the effect of external force or overload.
  • Page 393 2) Interrupt the power to the peripheral equipment and activate only the ERC3 actuator. If any error does not occur, it might be caused by noise. Take proper measures against noise. If the cause is due to 3) or 4), it is necessary to replace the ERC3.
  • Page 394 If the same failure occurs again, it is necessary to have an absolute reset. [Refer to Chapter 6, 6.1 Absolute Reset and Absolute Battery] Mismatched This error would not occur in ERC3. If occurs, please contact IAI.    ...
  • Page 395 Treatment : When the error is caused even when the power is re-input, please contact IAI. CPU error CPU in the controller inside the ERC3 motor unit is not working properly. Cause : 1) Faulty CPU. 2) Malfunction due to noise.
  • Page 396 ME0297-14E...

  • Page 397: Chapter 8 Actuator Maintenance Check

    Chapter 8 Actuator Maintenance Check 8.1 Inspection Items and Schedule Follow the maintenance inspection schedule below. It is assumed that the equipment is operating 8 hours per day. If the equipment is running continuously night and day or otherwise running at a high operating rate, inspect more often as needed.

  • Page 398: External Visual Inspection

    Caution: • An actuator after 6 months of storage may have caused a degradation of the grease. Supply grease before start using. [Refer to 8.6 “Grease Supply”] • Degradation speed of grease may differ depending on the environment of use (temperature, humidity and ambient conditions).

  • Page 399: Internal Inspections For Slider Type

    Change in the attached condition may cause the sheet to be mounted unevenly or impact the product life. In such cases, please contact IAI Sales Engineer Department. Also you may get hurt on the edge of the stainless steel sheet. Wear gloves when you work on it.

  • Page 400: Grease Supply

    8.6.1 Grease Supply for Slider Type [1] Other Types than Cleanroom Type (1) Grease Applied to Guide IAI uses the following grease in our plant. Guide Idemitsu Kosan Daphne Grease MP No.2 Other companies also sell similar types of grease. For details, give the above grease name to the manufacturer you want to purchase from and ask what corresponding product they have available.

  • Page 401: How To Supply Grease On Slider Type

    8.6.2 How to Supply Grease on Slider Type [1] Standard Type (Screw Cover Type) 1) Remove the thin-head screws with a 1.5mm hex wrench for SA5 and 2.0mm wrench for SA7. Thin-Head Screw 2) Detach the screw cover. Screw Cover 3) After cleaning up the guide on both sides, apply the grease.
  • Page 402 4) After cleaning up the ball screw, apply the grease by hand. Move the slider back and forth to evenly apply the grease. For some of the low lead actuators, the slider would not move manually with hand. Move it with JOG operation of the controller.

  • Page 403: Standard Type (Stainless Steel Sheet Type), Cleanroom Type

    [2] Standard Type (Stainless Steel Sheet Type), Cleanroom Type 1) Remove the screws and detach the side covers on both sides. Side Cover Side Cover Attachment Attachment Screws Screws Opposite Side of the Motor Motor Side Side Covers After Side Covers are Detached 2) On the guide part, insert a spatula between the slider and the base or apply grease with a grease injector while moving the slider back and forth.
  • Page 404 3) Apply the grease on the ball screw with hand after cleaning it, and move the slider back and forth to spread the grease. In this process, pay attention to the stainless steel sheet so that you would not touch and make it deformed.

  • Page 405: Grease Supply For Rod Type

    8.6.3 Grease Supply for Rod Type (1) Grease Applied to Ball Screw and Rod Sliding Part IAI uses the following grease in our plant. Ball Screw Kyodo Yushi Multitemp LRL 3 Use lithium grease spray for the maintenance work of ball screws. Make it 1 sec or less to apply the spray in one time.

  • Page 406: How To Supply Grease On Rod Type

    8.6.4 How to Supply Grease on Rod Type 1) Remove the thin-head screw with a 1.5mm hex wrench. 2) Slide the rod for more than the half of the stroke distance. For some of the low lead actuators, the rod would not move manually with hand. Move it with JOG operation of the controller.
  • Page 407 3) On the rod sliding part, apply grease by hand. Wipe off the old grease, and then supply new grease. 4) After applying the grease, move the rod back and forth so the grease spreads out evenly. For some of the low lead actuators, the rod would not move manually with hand. Move it with JOG operation of the controller.

  • Page 408: How To Replace And Adjust Stainless Steel Sheet

    8.6.5 How to Replace and Adjust Stainless Steel Sheet The screws and other components detached for the replacement will be necessary when rebuild the product. Prepare a storage box beforehand to keep the components in it. [1] Preparation (1) Items Required for Replacement Work •...

  • Page 409: Procedure For Replacement And Tuning

    [2] Procedure for Replacement and Tuning (1) Move the slider to the middle of the actuator (2) Remove the screws affixing the slider cover. For SA5C, there is a plate spring. Remove the spring. Standard Type (Stainless Steel Sheet Type) Condition with Slider Covers Detached (plate spring also removed) Clean Room Type Condition with Slider Covers Detached...
  • Page 410 (5) Adjust the stainless steel sheet tension. 1) Adjust the tension of stainless steel sheet by moving back and forth.. For Clean Type, make the roller pressed down to touch the side covers. It is not necessary for Standard Type since there is no roller. 2) Tune the tension of the sheet so the distance between the peak of the sheet and the top surface of the slider become as shown in the figure below and temporarily tighten the screws on the opposite side of the motor to hold the stainless steel sheet.

  • Page 411: Motor Replacement Process

    8.7 Motor Replacement Process [Items required for replacing the motor] • Motor Unit for Replacement • Hex wrench set [Procedure] 1) Remove the screw affixing the actuator and motor unit with 2.5mm hex wrench for SA5 and SA4 and 3.0mm wrench for RA7 and RA6. Screw connecting the Actuator and Motor Unit 2) Detach the motor unit.
  • Page 412 3) Make the profiles on the actuator side and motor unit side aligned so the projection matches to the slit. Make the projection and slit Apply grease to the coupling part. matched with each other. TL101Y grease made by NOK 4) Attach the motor unit for replacement with the projection being matched with the slit.

  • Page 413: Chapter 9 External Dimensions

    Chapter 9 External Dimensions 9.1 ERC3-SA5C Standard Type (Screw Cover Type) 20.5 20.5 2-φ4H7 depth 6 4-M4 depth 8 Datum Surface φ8 φ4.5 Detail: X (Attachment Hole and Datum Surface) 142.5 Stroke 55.3 2-φ4H7 depth 5.5 J-Oblong Hole, depth 5.5 (from base bottom) D×100P...

  • Page 414: Erc3-Sa7C

    9.2 ERC3-SA7C Standard Type (Screw Cover Type) 2-φ5H7 depth 10 Datum Surface 4-M5 depth 10 φ9.5 φ5.5 Detail: X (Attachment Hole and Datum Surface) 28.5 Stroke H-φ5.5 through φ9.5 countersink, depth 5.5 J-Oblong Hole, depth 6 (from base bottom) (from opposite side) G-M5 depth 9 D×100P...

  • Page 415: Erc3D, Erc3Cr-Sa5C Standard Type (Stainless Steel Sheet Type)

    9.3 ERC3D, ERC3CR-SA5C Standard Type (Stainless Steel Sheet Type), Cleanroom Type Note: Stainless steel sheet type is not equipped with vacuum or joint. 15.5 15.5 2-Ø4 H7 depth 4-M4 depth ( Ø4H7 Pitch 19 ±0.02 ±0.02) 105.7 (148.2) Moment Stroke 34.2 Datum Point for Offset Ø40(Rotation Range)

  • Page 416: Erc3D, Erc3Cr-Sa7C Standard Type (Stainless Steel Sheet Type)

    9.4 ERC3D, ERC3CR-SA7C Standard Type (Stainless Steel Sheet Type), Cleanroom Type Note: Stainless steel sheet type is not equipped with vacuum or joint. 20 20 20 4-M5 depth 2- Ø5H7 depth (Ø 5H7 Pitch ± 0.02) 32 ±0.02 134.5(185.5) Moment 20.5 Stroke 39.2...

  • Page 417: Erc3-Ra4C

    9.5 ERC3-RA4C Weight* Stroke With [kg] Brake Brake 328.5 378.5 428.5 478.5 528.5 578.5 * A model with brake increases the weight by 0.4kg. ME0297-14E...

  • Page 418: Erc3-Ra6C

    9.6 ERC3-RA6C Detail A Scale 2:1 10.5 4-M8 depth 16 ME SE F (Effective T-groove range) 176.5 Stroke 49.5 With Brake 227.5 M14×1.5 Supplied Square Nut for T-Groove Nut applied to Rod Tip (enclosed four units) Weight* Stroke With [kg]...

  • Page 419: Appendix

    Chapter 10 Appendix 10.1 Input and Output Response Performance When PIO Converter is Used When controlling ERC3 with using PIO converter, there is a delay in the response time as described below; 1) Input Delay Time of PIO Converter The digital input time constant with the hardware is 2ms at maximum. The digital input filter time with the firmware is 5ms at maximum.

  • Page 420: Way To Set Multiple Controllers With 1 Teaching Tool

    PIO converter. ERC3 should be in CON Mode. The following method cannot be applied if ERC3 is in the serial communication type. It is usually necessary to connect the teaching tool to the controllers one by one when making a setup to multiple controllers with one unit of teaching tool.

  • Page 421: Connecting Example

    10.2.1 Connecting Example Caution: Supply 0V to the SIO converter and each controller from the same power source. PC Software (Option) RS232C-compatible <RCM-101-MW> USB-compatible <RCM-101-USB> Teaching Pendant Cable included in PC software <RCB-CV-MW, CB-RCA-SIO□□□> <CB-SEL-USB030, RCB-CV-USB, CB-RCA-SIO□□□> SIO Converter (with Terminal Resistor) <RCB-TU-SIO-A>...

  • Page 422: Detailed Connection Diagram Of Communication Lines

    (Manufactured by AMP : 4-1473562-4) e-CON Connector Cover Color : GN (Manufactured by AMP : 4-1473562-4) Controller Housing Color : GN Link Cable ERC3 1st Unit ERC3 2nd Unit CB-RCB-CTL002 SIO Connector SIO Connector Controller Link Cable e-CON Connector CB-RCB-CTL002...

  • Page 423: Handling Of E-Con Connector (How To Connect)

    10.2.4 Handling of e-CON connector (how to connect) Clamp Lever 1) Check the applicable cable size. Check the applicable cable. If it is not applicable, Pin No. it may cause a connection failure or a breakage of the connector. 2) Check the pin numbers, do not reveal the sheath, and insert the cable till it reaches the end.

  • Page 424: Sio Converter

    10.2.5 SIO Converter The SIO converter converts the communication mode from RS232C to RS485 or vice versa. 7) e-CON Connector 2) Link-connection 1) Power/Emergency Stop Terminal Board (TB1) Terminal Board (TB2) 6) LED Indicators for Monitoring 3) D-sub, 9-pin Connector 5) PORT Switch 4) Mini DIN, 8-pin Connector 1) Power/Emergency Stop Terminal Board (TB2)
  • Page 425 2) Link-connection Terminal Board (TB1) This is the connection port to obtain communication connection with the controller. Connect terminal “A” on the left side to communication line SGA of the controller. (Terminal A is connected to pin 1 of (7) internally.) Connect terminal “B”...

  • Page 426: Communications Cable

    10.2.6 Communications Cable 1) Controller Link Cable (CB-RCB-CTL002) Controller Side 200mm e-CON Connector 3-1473562-4 (Housing Color : OR) Mini DIN Connector Signal Signal ME0297-14E...

  • Page 427: Conformity To Safety Category

    In this case, it is recommended to use a teaching pendant equipped with a dead man's switch (Model Code: TB-02D or TB-01D/DR). System I/O Connector ERC3 (The front (ENB*) is the lower side PIO Converter and the back (EMG*) is upper side.) TP Adaptor "RCB-LB-TGS"...

  • Page 428: Wiring And Setting Of Safety Circuit

    [2] Wiring and setting of safety circuit 1) Power supply To use safety relays and/or contactors of 24V DC specification in the safety circuit, the control power supply should be used only for the circuit as much as possible. (Do not use the same power source as the driving power supply for this controller.) It is the risk prevention treatment preparing for the cases such as the operation error of the safety circuit caused by not enough power capacity.
  • Page 429 ● Upper side EMG connector ● Lower side ENB connector EMG1- ENB1- EMG1+ ENB1+ EMG2- ENB2- EMG2+ ENB2+ EMGIN ENBIN EMGOUT ENBOUT Wiring Color Signal No. Wiring Color Signal No. ENB1- EMG1- ENB1+ EMG1+ ENB2- EMG2- AWG24 AWG24 ENB2+ EMG2+ ENBIN EMGIN ENBOUT...

  • Page 430: Examples Of Safety Circuits

    [3] Examples of safety circuits 1) In case of category 1 TB-02D or TB-01D/TB-01DR (or Dummy plug: DP-4S) PIO Converter Connection Cable CB-CON-LB□□□ TP Adapter for the Position Controller RCB-LB-TGS CB-TB1-GC□□□ EMG- Solenoid Contactor Motor Power Supply ME0297-14E...
  • Page 431 ● Detailed category 1 circuit example RCB-LB-TG PIO Converter Emergency Stop SW EMGA EMG1- VP24 EMG1+ TP Connection Detecting T24V EMG2- TP Detection EMG2+ T24V…Output EMGB Bypass relay…OPEN Enable SW TP Not Detected EMB1- T24V…Not Output Bypass relay…CLOSE EMB1+ EMB2- EMB2+ DC24V+ EMG−...
  • Page 432 In case of category 2 TB-02D or TB-01D/TB-01DR (or Dummy plug: DP-4S) PIO Converter Connection Cable CB-CON-LB□□□ TP Adapter for the Position Controller RCB-LB-TGS CB-TB1-GC□□□ Enable SW Enable SW Enable SW Emergency stop SW Reset SW G9SA-301 (OMRON) T11 A2 A1 41 33 23 13 42 34 24 14 T21 PE...
  • Page 433 ● Detailed category 2 circuit example RCB-LB-TG PIO Converter Emergency Stop SW EMGA EMG1- VP24 EMG1+ TP Connection Detecting T24V EMG2- TP Detection EMG2+ T24V…Output EMGB Bypass relay…OPEN Enable SW TP Not Detected EMB1- T24V…Not Output Bypass relay…CLOSE EMB1+ EMB2- EMB2+ DC24V+ EMG−...
  • Page 434 In case of category 3 or 4 TB-02D or TB-01D/TB-01DR (or Dummy plug: DP-4S) PIO Converter Connection Cable CB-CON-LB□□□ TP Adapter for the Position Controller RCB-LB-TGS CB-TB1-GC□□□ For Category 4, insert Reset Switch as shown in the diagram. For Category 3, layout Emergency Stop SW Emergency Stop SW Emergency Stop SW...
  • Page 435 ● Detailed category 3 or 4 circuit example RCB-LB-TG PIO Converter Emergency Stop SW EMGA EMG1- VP24 EMG1+ TP Connection Detecting T24V EMG2- TP Detection EMG2+ T24V…Output EMGB Bypass relay…OPEN Enable SW TP Not Detected EMB1- T24V…Not Output Bypass relay…CLOSE EMB1+ EMB2- EMB2+...

  • Page 436: Tp Adapter And Related Parts

    [4] TP adapter and Related Parts TP adapter external dimensions ME0297-14E...
  • Page 437 Connection Cable ● Controller/TP Adaptor Connection Cable Use this cable to connect the controller and TP adapter (RCB-LB-TGS). Model : CB-CON-LB005 (standard cable length : 0.5m) Maximum cable length : 2.0m CB-CON-LB□□□ Color Signal No. Signal Color ENBL ENBL EMGA EMGA EMGB EMGB...

  • Page 438: When Connecting Power Supply With + Grounding

    10.4 When Connecting Power Supply with + Grounding When using ERC3 with + grounding, there is a risk of short-circuit of 24V DC power supply if connected to the PC. This is because many PCs have the communication ground (GND) and the frame ground (FG) connected inside and short-circuit occurs through the frame ground.

  • Page 439: Example Of Basic Positioning Sequence (Pio Patterns 0 To 3 In Pio Converter)

    10.5 Example of Basic Positioning Sequence (PIO Patterns 0 to 3 in PIO Converter) This section shows an example in which a simple operation box directs ERC3 to move the actuator successively to three positions on an axis. 10.5.1 I/O Assignment...

  • Page 440: Ladder Sequence

    10.5.2 Ladder Sequence [1] Servo ON (Emergency Stop) Circuit It is presumed that the emergency stop release circuit installed in the operation box possesses the self-retaining circuit as shown in “3.1.3 [1] Emergency Stop Circuit”. When it comes to the emergency stop release condition, “Servo-on” signal from PLC to PCON turns ON.

  • Page 441: Pause Circuit

    [3] Pause Circuit Pause is provided by a single pushbutton. In a similar way as use of an alternate switch, push the button to make the actuator pause and push it again to release the pause of the actuator. Pushing the pushbutton leads the “pause command and pause lamp ON” state and pushing the pushbutton again brings “pause release command and pause lamp OFF”.

  • Page 442: Reset Circuit

    If the “Stop” button on the operation box is pushed during pause, the “Reset” signal sent from PLC to ERC3 and PIO converter are turned ON and the remaining moving distance is cancelled. In addition, this operation releases the pause. (It is because the pause is not required with no remaining moving distance.)

  • Page 443: Home Return Circuit

    [5] Home Return Circuit Similar to the operation circuit, this is (Interlock) used to determine whether the controller Turns the “Home return” signal OFF at completion of home return. can be operated. It is set as it would not be able to home return again after the home return (Confirmation of ready status of controller) operation is complete unless “Home Return Complete”...

  • Page 444: Decode Circuit Of Positioning Complete Position No

    [6] Decode Circuit of Positioning Complete Position No. The decode circuit converts the binary data of positioning complete position No. sent from ERC3 and PIO converter to PLC into the corresponding bit data. This is the timer to prevent the code reading error since the scanning is held independently by PLC and RC controller.

  • Page 445: Position 1 Operation Circuit

    • If the “Operation” lamp goes off, the operation circuit is reset entirely. When the “Stop” button is pushed, the actuator will stop at completion of the operation being executed. At emergency stop, the actuator is stopped immediately (which is the function of ERC3 and PIO Converter ). ME0297-14E...

  • Page 446: Position 2 Operation Circuit

    [9] Position 2 Operation Circuit The main circuit is designed to process and manage signals “start” → “moving” → “positioning complete” to move the actuator to position No.2. This circuit indicates the same sequence as that of position No.1. Startup Startup Auxiliary Position 2 AUX12...

  • Page 447: Position 3 Operation Circuit

    [10] Position 3 Operation Circuit The main circuit is designed to process and manage signals “start” → “moving” → “positioning complete” to move the actuator to position No.3. This circuit indicates the same sequence as that of position No.1. Startup Startup Auxiliary Position 3 AUX15...

  • Page 448: Commanded Position No. Output Ready Circuit

    [11] Commanded Position No. Output Ready Circuit The ready circuit is designed to hold start command and output commanded position No. in the binary code. Interlock is taken so that position No. command may not be specified incorrectly. Position 1 Set AUX9 AUX12 AUX15...

  • Page 449: Commanded Position No. Output Circuit

    [12] Commanded Position No. Output Circuit Depending on the result of the ready circuit, this circuit converts position No. to the binary code and outputs the data from PLC to ERC3 and PIO converter. [Position No.1] OUT8 AUX18 Command Position 1...

  • Page 450: Other Display Circuits (Zone 1, Position Zone, And Manual Mode)

    [14] Other Display Circuits (Zone 1, Position Zone, and Manual Mode) OUT6 Zone 1 Display ZONE L ZONE1 Zone 1 IN10 OUT6 Position Zone Display PZONE L PZONE Position Zone IN 1 1 OUT7 Manual Mode Display CSTR RMDS Operation Mode [Reference] Programs and functions of PLC are expressed differently depending on manufacturers.

  • Page 451: Life

    10.6 Life The mechanical life of the actuator is represented by that of the guide receiving the greatest moment load. Operation life of the linear guide is to be determined by the total driving distance which can reach without having 90% flaking (peeling on rail surface). Operation life can be figured out with the calculation method shown below.

  • Page 452: Operation Life

    Attachment on spots Attached condition * As the figures are those in common for each manual, they are not for ERC3. Replace to figures for ERC3 and select the attachment coefficient. * Even when in attachment in whole area, and the actuator is seated in the whole length of the product, select 1.2 or 1.5 for the attachment coefficient depending on the position of screw fixing.

  • Page 453: Warranty

    Chapter 11 Warranty 11.1 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  2,500 operational hours 11.2 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 454: Limited Liability

    11.4 Limited Liability (1) We shall assume no liability for any special damage, consequential loss or passive loss such as a loss of expected profit arising from or in connection with our product. (2) We shall not be liable for any program or control method created by the customer to operate our product or for the result of such program or control method.

  • Page 455: Change History

    Pg. 74 to 77 Weight added to appearance drawing Pg. 160 and 161 Contact CR load current changed Pg. 203 Instruction added for home return operation in PIO Pattern 2 of ERC3 main unit Pg. 353 IN13 b contact changed to a contact Pg.
  • Page 456 Revision Date Revision Description 2012.06 Seventh edition Revised overall 2012.06 Edition 7B Note corrected 2012.10 Eighth edition Pg. 423 ”2,500 operational hours” added to Warranty Period. 2013.01 Ninth edition Slider Standard Type (Stainless Steel Sheet Type) and Cleanroom Type added. 2013.02 Tenth edition Pg.

  • Page 457: Chapter 9 Description Revised Regarding Weight

    Revision Date Revision Description 2016.04 Edition 13C Pg. 385, 386, 395 The contents about grease supply on rod sliding surface and cleaning are added 2016.08 Edition 13D Pg. 317, 348 Default factory setting for absolute battery retention time are corrected to 0 from 2 2016.12 Edition 13E...
  • Page 458 Revision Date Revision Description 2023.12 Edition 14E Pg. 61 B11 in input and output connection diagram corrected from output to input Pg. 73 Descriptions revised Pg. 176 Correction made to 2) Pattern Numbers in Power Supply and Emergency Stop Release ME0297-14E...

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