IAI ERC2 Installation manual

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

Please Read Before Use
Thank you for purchasing our product.
This Operation Manual explains the handling methods, structure and maintenance of this product, among others,
providing the information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure
safe use of the product.
The DVD that comes with the product contains operation manuals for IAI products.
When using the product, refer to the necessary portions of the applicable operation manual by printing them out or
displaying them on a PC.
After reading the Operation Manual, keep it in a convenient place so that whoever is handling this product can
reference it quickly when necessary.
[Important]
This Operation Manual is original.
The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI shall assume no
responsibility for the outcome of any operation not specified herein.
Information contained in this Operation Manual is subject to change without notice for the purpose of product
improvement.
If you have any question or comment regarding the content of this manual, please contact the IAI sales office near
you.
Using or copying all or part of this Operation Manual without permission is prohibited.
The company names, names of products and trademarks of each company shown in the sentences are registered
trademarks.

CAUTION
1. Using Multiple 24-V Power Supplies
If multiple 24-V power supplies are used, always connect the 0-V lines of all power supplies.
If not, damage to the controller board, SIO converter or other components may occur.
[Connection Example]
24V
0V
24V
0V
24V
0V
24V
0V
24V
0V
24-V power supply
[1]
24-V power supply
[2]
24-V power supply
[3]
24-V power supply
[4]
24-V power supply
[5]
SIO
converter
PLC
PIO unit
Actuator 1
Actuator 2
Actuator 3
Actuator 4

CAUTION
2. PC Software and Teaching Pendant Models
This product offers new functions not available in the conventional ERC series.
To support these new functions, the communication protocol has been changed to a general Modbus-
compliant protocol. Accordingly, the PC software programs and teaching pendants that have been used
with the ERC series are no longer compatible with the ERC2 series.
Select a compatible program or teaching pendant from among the models listed below.
Model number Remarks
PC software (with RS232C
communication cable) RCM-101-MW
PC software (with USB
communication cable) RCM-101-USB
Teaching pendant RCM-T, RCM-TD
Simple teaching pendant RCM-E
Data setting unit RCM-P
These software programs/teaching
pedants can be used with the ERC
series.
3. Backup of Latest Data
The built-in controller of this actuator uses a nonvolatile memory to store position table data and
parameters. Normally data is retained after the power has been cut off, but stored data will be lost if the
nonvolatile memory is damaged.
Regular backup of latest position table data and parameters not only ensures that your important data is
safeguarded, but it also saves the data recovery time when a need arises to replace the controller board
for some reason.
To back up your data, do one of the following:
[1] Save the data to a hard disk or other storage media from the PC software.
[2] Create a position table sheet or parameter sheet and write down the settings.
4. Pamphlet on Modbus Protocols
You can download a pamphlet compiling Modbus protocols from the operation manual download page on
IAI’s website:
website:www.intelligentactuator.com
If you wish to obtain this pamphlet, please contact your IAI sales representative.

CE Marking
If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual
(ME0287) that is provided separately.

Table of Contents
Safety Guide .................................................................................................................................................. 1
1. Overview ................................................................................................................................................ 9
1.1 Introduction .................................................................................................................................. 9
1.2 Key Features and Functions......................................................................................................10
1.3 Differences from Air Cylinder Control ........................................................................................ 11
1.4 Meaning of the Model Number .................................................................................................. 13
1.5 Specifications............................................................................................................................. 14
1.5.1 Correlation Diagrams of Speed and Payload Capacity – Slider Type .......................... 15
1.5.2 Correlation Diagrams of Speed and Payload Capacity – Rod Type............................. 16
1.5.3 The sound pressure level of this product does not exceed 70 dB................................ 17
1.6 Warranty ................................................................................................................................... 20
1.7 Transportation and Handling ..................................................................................................... 20
1.7.1 Handling before Unpacking .......................................................................................... 20
1.7.2 Handling after Unpacking.............................................................................................. 20
1.8 Installation Environment and Noise Elimination ........................................................................ 21
1.8.1 Installation Environment................................................................................................ 21
1.8.2 Storage Environment .................................................................................................... 21
1.8.3 Power Supply................................................................................................................22
1.8.4 Noise Elimination ..........................................................................................................22
1.9 Cabling....................................................................................................................................... 24
2. Installation ............................................................................................................................................ 27
2.1 Name of Each Part .................................................................................................................... 27
2.1.1 Slider Type (SA6C/SA7C)............................................................................................. 27
2.1.2 Rod Type (RA6C/RA7C) ............................................................................................... 28
2.1.3 (1) Rod Type with a Single Guide (RGS6C/RGS7C).................................................... 28
(2) Rod Type with Double Guides (RGD6C/RGD7C)................................................... 28
2.2 Installation.................................................................................................................................. 29
2.2.1 Slider Type .................................................................................................................... 29
2.2.2 Rod Type....................................................................................................................... 30
2.2.3 Installing the Load......................................................................................................... 32
3. Electrical Specifications ....................................................................................................................... 34
3.1 Controller ................................................................................................................................... 34
3.2 Input/Output Interfaces .............................................................................................................. 35
3.2.1 Extension Cable............................................................................................................ 36
3.3 SIO Converter (Optional)........................................................................................................... 37
4. Wiring ................................................................................................................................................... 39
4.1 Basic Configuration with SIO Converter .................................................................................... 39
4.1.1 SIO Communication Connection Using a Relay Terminal Block .................................. 41
4.1.2 SIO Communication Connection Using a 4-Way Junction ........................................... 42
4.1.3 Address Assignment ..................................................................................................... 43
4.2 Configuration Using a Gateway Unit ......................................................................................... 44
4.2.1 SIO Communication Connection Using a Relay Terminal Block .................................. 44
4.2.2 SIO Communication Connection Using a 4-Way Junction ........................................... 45

4.2.3 Connecting an Emergency Stop Circuit, Etc................................................................. 46
5. Explanation of Operating Functions..................................................................................................... 47
5.1 Description of Position Table ..................................................................................................... 48
5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value ........................... 52
5.2 Data Set in the Numerical Specification Mode .......................................................................... 54
5.3 Explanation of Functions ........................................................................................................... 54
5.3.1 Control Signals and Control Data ................................................................................. 56
5.3.2 Timings after Power On ................................................................................................ 62
5.3.3 Home Return Operation................................................................................................ 64
5.3.4 Positioning Operation.................................................................................................... 66
5.3.5 Push & Hold Operation ................................................................................................. 70
5.3.6 Pause............................................................................................................................ 74
5.3.7 Speed Change during Movement ................................................................................. 75
5.3.8 Operation at Different Acceleration and Deceleration .................................................. 77
5.3.9 Zone Signal................................................................................................................... 78
5.3.10 Pitch Feed by Incremental Specification....................................................................... 79
5.3.11 Power-Saving Mode at Standby Positions.................................................................... 83
6. Parameter Settings .............................................................................................................................. 84
6.1 Parameter Table ........................................................................................................................ 84
6.2 Detailed Explanation of Parameters .......................................................................................... 85
6.2.1 Parameters Relating to the Actuator Stroke Range...................................................... 85
6.2.2 Parameters Relating to the Actuator Operating Characteristics................................... 87
6.2.3 Parameters Relating to the External Interface.............................................................. 91
6.2.4 Servo Gain Adjustment ................................................................................................. 93
7. Troubleshooting ................................................................................................................................... 95
7.1 Action to Be Taken upon Occurrence of Problem...................................................................... 95
7.2 Alarm Level Classification.......................................................................................................... 96
7.2.1 How to Reset Alarms .................................................................................................... 96
7.3 Alarm Description and Cause/Action......................................................................................... 97
7.4 Messages Displayed during Operation Using the Teaching Pendant or PC Software............ 102
7.5 Specific Problems .................................................................................................................... 104
8. Maintenance and Inspection .............................................................................................................. 106
8.1 Inspection Items and Schedule ............................................................................................... 106
8.2 Visual Inspection of Appearance ............................................................................................. 106
8.3 Cleaning................................................................................................................................... 106
8.4 Internal Check (Slider Type) .................................................................................................... 107
8.5 Internal Cleaning (Slider Type) ................................................................................................ 108
8.6 Greasing the Guide (Slider Type) ............................................................................................ 108
8.7 Greasing the Ball Screw (Slider Type)..................................................................................... 110
8.8 Greasing the Rod Slide Surface .............................................................................................. 111
8.9 Motor Replacement Procedure................................................................................................ 112
9. Operation Examples .......................................................................................................................... 114
10. Appendix ........................................................................................................................................... 115
.......................................................................................................................... 115
..........................................................................................................................115
..........................................................................................................................116
10.1 External Dimensions
10.1.1 ERC2-SA6C
10.1.2 ERC2-SA7C

.......................................................................................................................... 117
10.1.3 ERC2-RA6C
.......................................................................................................................... 118
10.1.4 ERC2-RA7C
....................................................................................................................... 119
10.1.5 ERC2-RGS6C
....................................................................................................................... 119
10.1.6 ERC2-RGS7C
....................................................................................................................... 120
10.1.7 ERC2-RGD6C
....................................................................................................................... 120
10.1.8 ERC2-RGD7C
Recording of Position Table................................................................................................................ 121
Parameter Records.............................................................................................................................. 124
Change History................................................................................................................................ 125
10.2
10.3

1
Safety Guide
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Safety Precautions for Our Products
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2
No. Operation
Description Description
2 Transportation ƔWhen carrying a heavy object, do the work with two or more persons or
utilize equipment such as crane.
ƔWhen 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.
ƔWhen in transportation, consider well about the positions to hold, weight
and weight balance and pay special attention to the carried object so it
would not get hit or dropped.
ƔTransport it using an appropriate transportation measure.
The actuators available for transportation with a crane have eyebolts
attached or there are tapped holes to attach bolts. Follow the instructions
in the instruction manual for each model.
ƔDo not step or sit on the package.
ƔDo not put any heavy thing that can deform the package, on it.
ƔWhen using a crane capable of 1t or more of weight, have an operator
who has qualifications for crane operation and sling work.
ƔWhen using a crane or equivalent equipments, make sure not to hang a
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ƔUse a hook that is suitable for the load. Consider the safety factor of the
hook in such factors as shear strength.
ƔDo not get on the load that is hung on a crane.
ƔDo not leave a load hung up with a crane.
ƔDo not stand under the load that is hung up with a crane.
3 Storage and
Preservation
ƔThe storage and preservation environment conforms to the installation
environment. However, especially give consideration to the prevention of
condensation.
ƔStore the products with a consideration not to fall them over or drop due to
an act of God such as earthquake.
4 Installation
and Start
(1) Installation of Robot Main Body and Controller, etc.
ƔMake sure to securely hold and fix the product (including the work part). A
fall, drop or abnormal motion of the product may cause a damage or injury.
Also, be equipped for a fall-over or drop due to an act of God such as
earthquake.
ƔDo not get on or put anything on the product. Failure to do so may cause
an accidental fall, injury or damage to the product due to a drop of
anything, malfunction of the product, performance degradation, or
shortening of its life.
ƔWhen using the product in any of the places specified below, provide a
sufficient shield.
1) Location where electric noise is generated
2) Location where high electrical or magnetic field is present
3) Location with the mains or power lines passing nearby
4) Location where the product may come in contact with water, oil or
chemical droplets

3
No. Operation
Description Description
(2) Cable Wiring
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and controller, and for the teaching tool.
ƔDo not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not
coil it around. Do not insert it. Do not put any heavy thing on it. Failure to
do so may cause a fire, electric shock or malfunction due to leakage or
continuity error.
ƔPerform the wiring for the product, after turning OFF the power to the unit,
so that there is no wiring error.
ƔWhen the direct current power (+24V) is connected, take the great care of
the directions of positive and negative poles. If the connection direction is
not correct, it might cause a fire, product breakdown or malfunction.
ƔConnect the cable connector securely so that there is no disconnection or
looseness. Failure to do so may cause a fire, electric shock or malfunction
of the product.
ƔNever cut and/or reconnect the cables supplied with the product for the
purpose of extending or shortening the cable length. Failure to do so may
cause the product to malfunction or cause fire.
4 Installation
and Start
(3) Grounding
ƔThe grounding operation should be performed to prevent an electric shock
or electrostatic charge, enhance the noise-resistance ability and control
the unnecessary electromagnetic radiation.
ƔFor the ground terminal on the AC power cable of the controller and the
grounding plate in the control panel, make sure to use a twisted pair cable
with wire thickness 0.5mm2(AWG20 or equivalent) or more for grounding
work. For security grounding, it is necessary to select an appropriate wire
thickness suitable for the load. Perform wiring that satisfies the
specifications (electrical equipment technical standards).
ƔPerform Class D Grounding (former Class 3 Grounding with ground
resistance 100or below).

4
No. Operation
Description Description
4 Installation
and Start
(4) Safety Measures
ƔWhen 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.
ƔWhen the product is under operation or in the ready mode, take the safety
measures (such as the installation of safety and protection fence) so that
nobody can enter the area within tKHURERW¶VPRYDEOHUDQJH:KHQWKH
robot under operation is touched, it may result in death or serious injury.
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input.
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understand them well.
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so that any third person can not operate the switches carelessly.
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* Safety protection Fence : In the case that there is no safety protection
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5
No. Operation
Description Description
6 Trial Operation ƔWhen 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.
ƔAfter the teaching or programming operation, perform the check operation
one step by one step and then shift to the automatic operation.
ƔWhen the check operation is to be performed inside the safety protection
fence, perform the check operation using the previously specified work
procedure like the teaching operation.
ƔMake sure to perform the programmed operation check at the safety
speed. Failure to do so may result in an accident due to unexpected
motion caused by a program error, etc.
ƔDo not touch the terminal block or any of the various setting switches in
the power ON mode. Failure to do so may result in an electric shock or
malfunction.
7 Automatic
Operation
ƔCheck before starting the automatic operation or rebooting after operation
stop that there is nobody in the safety protection fence.
ƔBefore starting automatic operation, make sure that all peripheral
equipment is in an automatic-operation-ready state and there is no alarm
indication.
ƔMake sure to operate automatic operation start from outside of the safety
protection fence.
ƔIn the case that there is any abnormal heating, smoke, offensive smell, or
abnormal noise in the product, immediately stop the machine and turn
OFF the power switch. Failure to do so may result in a fire or damage to
the product.
ƔWhen a power failure occurs, turn OFF the power switch. Failure to do so
may cause an injury or damage to the product, due to a sudden motion of
the product in the recovery operation from the power failure.

6
No. Operation
Description Description
8 Maintenance
and Inspection
ƔWhen 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.
ƔPerform the work out of the safety protection fence, if possible. In the case
that the operation is to be performed unavoidably inside the safety
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sure that all the workers acknowledge and understand them well.
ƔWhen the work is to be performed inside the safety protection fence,
basically turn OFF the power switch.
ƔWhen the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so that
the unit can be stopped any time in an emergency.
ƔWhen the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
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ƔFor the grease for the guide or ball screw, use appropriate grease
according to the Instruction Manual for each model.
ƔDo not perform the dielectric strength test. Failure to do so may result in a
damage to the product.
ƔWhen releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
ƔThe slider or rod may get misaligned OFF the stop position if the servo is
turned OFF. Be careful not to get injured or damaged due to an
unnecessary operation.
ƔPay attention not to lose the cover or untightened screws, and make sure
to put the product back to the original condition after maintenance and
inspection works.
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fence, the movable range should be indicated.
9 Modification
and Dismantle
ƔDo not modify, disassemble, assemble or use of maintenance parts not
specified based at your own discretion.
10 Disposal ƔWhen the product becomes no longer usable or necessary, dispose of it
properly as an industrial waste.
ƔWhen removing the actuator for disposal, pay attention to drop of
components when detaching screws.
ƔDo not put the product in a fire when disposing of it.
The product may burst or generate toxic gases.
11 Other ƔDo not come close to the product or the harnesses if you are a person
who requires a support of medical devices such as a pacemaker. Doing so
may affect the performance of your medical device.
Ɣ6HH2YHUVHDV6SHFLILFDWLRQV&RPSliance Manual to check whether
complies if necessary.
ƔFor the handling of actuators and controllers, follow the dedicated
instruction manual of each unit to ensure the safety.

7
Alert Indication
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9
1. Overview
1. Overview
1.1 Introduction
Thank you for purchasing the Easy All-in-One ROBO Cylinder (hereinafter referred to as “ERC2-SE”).
This product retains all benefits of the conventional ERC series, while incorporating new features that provide
greater convenience and enhanced safety to the users.
Among the ERC2 Series actuators, this product can be operated via serial communication in the position number
specification mode or the direct numerical specification mode.
The following two communication patterns are supported by serial communication systems:
[1] Communicate with a host PLC, etc., via a gateway unit in various field network environments (DeviceNet,
CC-Link and Profibus).
[2] Communicate serially with a PC or PLC via a SIO converter based on the RS-232C protocol.
Please read this manual carefully and handle the product with utmost care while ensuring its correct operation.
It is advised that you also peruse the operation manual for your gateway unit as well as the Operation Manual for
Serial Communication Protocol.
When starting your system or in the event of failure, also refer to the operation manuals for the teaching pendant,
PC software and other components you are using with this product.
This manual does not cover all possible operations other than normal operations, or unexpected events
such as complex signal changes resulting from operating the product at critical timings.
Accordingly, think of any item not specifically mentioned in this manual as “prohibited.”
* We have made every effort to ensure accuracy of the information provided in this manual. Should you find an
error, however, or if you have any comment, please contact IAI.
Keep this manual in a convenient place so it can be referenced readily when necessary.

10
1. Overview
1.2 Key Features and Functions
(1) Input/output of control signals by means of RS485 serial communication (conforming to the Modbus
protocol)
(2) 64 positioning points
(3) Variable zone output boundaries
Before, zone output boundaries were set by parameters and therefore fixed. For greater convenience, this
product permits setting of zone output boundaries in the position table. (Available in the position number
specification mode only)
Set desired boundaries to prevent contact with peripheral equipment, shorten the tact time, etc.
(4) Different acceleration and deceleration settings (Available in the position number specification mode only)
Acceleration and deceleration can be set differently in the position table.
In situations where shock and vibration upon stopping must be minimized depending on the material or
shape of the load, you can decrease only the deceleration to allow the actuator to stop along a gradual
deceleration curve.
(5) Limitation of moving speed during adjustment by trial operation
During adjustment by trial operation, the moving speed of the actuator can be limited to ensure safety.
(6) Power-saving measure
In general, pulse motors generate greater holding current than AC servo motors in a standstill state.
Accordingly, we provide a power-saving mode to conserve electricity in situations where the actuator stands
by for a long period.