IAI PCON-CA User manual

PCON-CA/CFA/CB/CFB,
ACON-CA/CB/CGB, DCON-CA/CB/CGB
First Step Guide Sixth Edition
Thank you for purchasing our product.
Make sure to read the Safety Guide and detailed Instruction Manual (DVD) included with the product in addition to this First
Step Guide to ensure correct use. This Instruction Manual is original.
• Using or copying all or part of this Instruction Manual without permission is prohibited.
• The company names, names of products and trademarks of each company shown in the sentences are registered
trademarks.
• EtherCAT® is a registered mark of Beckoff Automation GmbH.
• EtherNet/IP is a trademark used under the license of ODVA.
Product Check
The standard configuration of this product is comprised of the following parts.
If you find any fault with the product you have received, or any missing parts, contact us or our distributor.
1. Parts
No. Part Name Model Reference
1 Controller Main Body Refer to “How to read the model plate”, “How to read
the model of the controller”
Accessories
2 Power Connector FMC1.5/8-ST-3.5 (Supplier : PHOENIX CONTACT)
Recommended cable size
AWG16 to 20
(1.25 to 0.5mm2)
3 Absolute Battery (Option) AB-7 or SEP-ABU* If applicable for Simple Absolute
Type
4 Serial Absolute Battery (Option) AB-5 If applicable for Serial Absolute
Type (for ACON only)
5 First Step Guide
6 Instruction Manual (DVD)
7 Safety Guide
2. Teaching Tool (to be purchased separately)
A teaching tool, such as PC Software, is necessary when performing programming and commissioning, such
as editing position data or parameters.
Please utilise any of the following teaching tools.
No. Part Name Model
1 PC Software
(with RS232C converter adapter + external equipment communication cable) RCM-101-MW
2 PC Software
(with USB converter adapter + USB cable + external equipment communication cable) RCM-101-USB
3 Touch Panel Teaching TB-01
4 Touch Panel Teaching (with Deadman Switch Attached on the Left side) TB-01D
5 Touch Panel Teaching (with Deadman Switch Attached on the Right side) TB-01DR
6 Touch Panel Teaching CON-PTA
7 Touch Panel Teaching (with Deadman Switch) CON-PDA
8 Touch Panel Teaching (with Deadman Switch + TP Adapter (RCB-LB-TG)) CON-PGAS
3. Instruction Manuals related to this product, which are contained in the Instruction Manual (DVD).
No. Name Manual No.
1 PCON-CA/CFA Controller Instruction Manual ME0289
2 PCON-CB/CFB Controller Instruction Manual ME0342
3 ACON-CA, DCON-CA Controller Instruction Manual ME0326
4 ACON-CB Series Controller, DCON-CB Series Controller, Instruction Manual ME0343
5 PC Software RCM-101-MW/RCM-101-USB Instruction Manual ME0155
6 Touch Panel Teaching CON-PTA/PDA/PGA Instruction Manual ME0295
7 Instruction Manual for the Serial Communication [for Modbus] ME0162
8 CC-Link Instruction Manual ME0254
9 DeviceNet Instruction Manual ME0256
10 PROFIBUS-DP Instruction Manual ME0258
11 CompoNet Instruction Manual ME0220
12 MECHATROLINK-Ⅰ/Ⅱ Instruction Manual ME0221
13 EtherCAT Instruction Manual ME0273
14 EtherNet/IP Instruction Manual ME0278
15 PROFINET-IO Instruction Manual ME0333
4. How to read the model plate
5. How to read the model of the controller
z PCON
PCON-CA-56P WAI-EP-2-0-ABU-DN-**
z ACON
ACON-CA-30 I-EC-2-0-AB-DN-**
z DCON
DCON-CA-3 I-EP-2-0-DN-**
Basic Specifications
PCON List of Specifications
Description
Item PCON-CA/CB/CGB PCON-CFA/CFB/CGFB
Number of controlled axes 1-axis
Power-supply Voltage 24V DC ±10%
20P, 28P, 28SP MAX. 1A
42P, 56P MAX. 2A
RCP2
RCP3
Motor
Type
86P Rated 4.2A / MAX. 6A
High-thrust function
is disabled MAX.2.0A
28P, 35P, 42P,
56P
High-thrust function
is enabled
Rated 3.5A /
MAX. 4.2A
Load
Capacity
(including
control side
current
consumption)
(Note1)
RCP4
RCP5
RCP6
Motor
Type
60P, 86P Rated 4.2A / MAX. 6A
Power Supply for Electromagnetic Brake
(for actuator equipped with brake) 24V DC ±10% 0.15A (MAX.)
RCP2, RCP3 5W 26.4W Heat Generation
RCP4 to RCP6 3W
Rush Current (Note2) 8.3A 10A
Transient Power Cutoff Durability MAX. 500μs
Motor Control System Weak field-magnet vector control
RCP2 to RCP5 Incremental Encoder, Battery-less Encoder Resolution 800pulse/rev Corresponding
Encoder RCP6 Battery-less Encoder Resolution 8192pulse/rev
Actuator Cable Length MAX. 20m
Serial Communication Interface
(SIO Port)
RS485 : 1 CH (based on Modbus Protocol RTU/ASCII)
Speed : 9.6 to 230.4Kbps
Control available with serial communication in the modes other than the pulse
train
PIO Type Signal I/O dedicated for 24V DC (selected from NPN/PNP) … Input 16 points
max., output 16 points max.
Cable length MAX. 10m
External Interface
Fieldbus Type DeviceNet, CC-Link, PROFIBUS-DP, CompoNet, MECHATROLINK,
EtherCAT, EtherNet/IP, PROFINET-IO
Data Setting and Input PC Software, Touch Panel Teaching, Teaching Pendant
Data Retention Memory Saves position data and parameters to non-volatile memory
(There is no limitation to the number of times data may be written.)
Operation Mode Positioner Mode/Pulse Train Control Mode (selected by parameter setting)
Number of Positions in Positioner Mode Standard 64 points, MAX. 512 points (PIO Type)
(Note) Number of positions differs depending on the selection in PIO pattern.
Differential System (Line Driver System) : MAX. 200kpps
Cable length MAX. 10m
Input Pulse Frequency
Open Collector System : Not applicable.
* If the host applies the open collector output, prepare AK-04 (option) separately
to convert to the differential type.
Command Pulse Multiplying
Factor
(Electrical Gear : A/B)
1/50 < A/B < 50/1
Setting Range of A and B (set to parameter) : 1 to 4096
Pulse Train
Interface
Feedback Pulse Output None
LED Display
(mounted on Front Panel)
SV (GN)/ALM (RD) : Servo ON/Alarm generated
STS0 to 3 : Status display
RDY (GN)/ALM (RD) : Absolute function in normal / absolute function error (for
the simple absolute type)
1, 0 (GN) (RD) : Absolute function status display (for the simple absolute
type)
Electromagnetic Brake Compulsory
Release Switch (mounted on Front Panel)
Switching NOM (standard)/BK RLS (compulsory release)
Insulation Resistance 500V DC 10MΩ or more
Protection Function against Electric Shock Class I basic insulation
Incremental Type Screw fixed type : 250g or less
DIN rail fixed type : 285g or less
Screw fixed type : 270g or less
DIN rail fixed type : 305g or less
Weight (Note3)
Simple Absolute Type
(including 190g for battery)
Screw fixed type : 450g or less
DIN rail fixed type : 485g or less
Cooling Method Natural air-cooling Forced air-cooling
External dimensions Screw fixed type : 35W×178.5H×69.1D
DIN rail fixed type : 35W×185H×77.6D
Screw fixed type : 35W×190H×69.1D
DIN rail fixed type : 35W×196.3H×77.6D
Surrounding Air
Temperature
0 to 40°C
Surrounding Humidity 85%RH or less (non-condensing)
Surrounding
Environment
[Refer to Installation Environment]
Surrounding Storage
Temperature
-20 to 70°C (Excluding battery)
Usage Altitude 1000m or less
Protection Class IP20
Environment
Vibration Durability Frequency 10 to 57Hz / Swing width : 0.075mm
Frequency 57 to 150Hz / Acceleration 9.8m/s2
XYZ directions Sweep time : 10 minutes Number of sweep : 10 times
Note1 Add an additional 0.3A inrush for Fieldbus Types.
Note2 In-rush current will flow for approximately 5msec after the power is turned on (at 40°C).
Note that the value of in-rush current differs depending on the impedance of the power supply line.
Note3 Add an additional 30g for Fieldbus Type of CA/CB/CGB Type. Add an additional 10g for Fieldbus Type of
CFA/CFB/CGFB Type .
Warning : Operation of this equipment requires detailed installation and operation instructions which are
provided on the DVD Manual included in the box this device was packaged in. It should be retained
with this device at all times.
A hardcopy of the Manual can be requested by contacting your nearest IAI Sales Office listed at
the back cove
r
of the Instruction Manual or on the First Step Guide.
Serial number
Model
Model
SER NO.
Input
Output
Actuator
**
CAUTION: Connect the wiring correctly and
properly, use IAI specified cables
or min 60°C Cu wire.
IP20
*********
*********
DC24V A
0-24Vac,3ph,0-333Hz, A
*****
<Series>
<Type>
CA/CB : Standard Type
CFA/CFB : High-Thrust Actuator
Connection Type
CGB : Sagety Categories Complied Type
CGFB : High-Thrust Actuator
Connection Sagety Categories
Complied Type
<Detail of Connected Axis>
[Motor Type]
20P : 20□ pulse motor, 20SP : 20□ pulse motor,
28P : 28□ pulse motor, 28SP : 28□ pulse motor,
35P : 35□ pulse motor
42P : 42□ pulse motor, 42SP : 42□ pulse motor
56P : 56□ pulse motor, 56SP : 56□ pulse motor
60P : 60□ pulse motor, 86P : 86□ pulse motor
[Encoder Type]
WAI : Incremental / Battery-less Absolute Shared
SA : Simple Absolute
<I/O Type>
NP : NPN Type (Sync. Type) (Standard),
PN : PNP Type (Source Type),
PLN : Pulse Train Control NPN Type (Sync. Type),
PLP : Pulse Train Control PNP Type (Source Type),
DV : DeviceNet Connection Type, CC : CC-Link Connection Type,
PR : PROFIBUS-DP Connection Type, CN : CompoNet Connection Type,
ML : MECHATROLINK-Ⅰ/ⅡConnection Type, EC : EtherCAT Connection Type,
EP : EtherNet/IP Connection Type, PRT : PROFINET-IO Connection Type
<Identification for IAI use only>
* There is no identification in some cases.
<Type of Installation>
(Not Specified) : Screw Attachment Type
DN : DIN Rail Mounting Type
<Applicable to Simplified Absolute Unit>
AB : Simple Absolute Type
(With the Absolute Battery)
ABU : Simple Absolute Type
(With the Absolute Battery Unit
(SEP-ABU))
ABUN : Simple Absolute Type
(With no Absolute Battery)
<Power-supply Voltage>
0 : 24V DC
<I/O Cable Length>
0 : Equipped with no cable
2 : 2m (Standard)
3 : 3m
5 : 5m
<Series>
<Type>
CA/CB : Standard Type
CGB : Safety Categories Complied Type
<Detail of Connected Axis>
[Motor Type]
2 : 2W AC servo motor
5 : 5W AC servo motor
10 : 10W AC servo motor
20S : 20W AC servo motor
20 : 20W AC servo motor
30 : 30W AC servo motor
[Encoder Type]
WAI : Incremental/Battery-less Absolute Shared
(CB dedicated)
I : Incremental
A : Absolute
<I/O Type>
NP : NPN Type (Sync. Type) (Standard),
PN : PNP Type (Source Type),
PLN : Pulse Train Control NPN Type (Sync. Type),
PLP : Pulse Train Control PNP Type (Source Type),
DV : DeviceNet Connection Type, CC : CC-Link Connection Type,
PR : PROFIBUS-DP Connection Type, CN : CompoNet Connection Type,
ML : MECHATROLINK-Ⅰ/ⅡConnection Type, EC : EtherCAT Connection Type,
EP : EtherNet/IP Connection Type, PRT : PROFINET-IO Connection Type
<Identification for IAI use only>
* There is no identification in some cases.
<Type of Installation>
(Not Specified) : Screw Attachment Type
DN : DIN Rail Mounting Type
<Applicable to Simplified Absolute Unit>
AB : Simple Absolute Type
(With the Absolute Battery)
ABU : Simple Absolute Type
(With the Absolute Battery Unit
(SEP-ABU))
ABUN : Simple Absolute Type
(With no Absolute Battery)
<Power-supply Voltage>
0 : 24V DC
<I/O Cable Length>
0 : Equipped with no cable
2 : 2m (Standard)
3 : 3m
5 : 5m
<Series>
<Type>
CA/CB : Standard Type
CGB : Safety Categories Complied Type
<Detail of Connected Axis>
[Motor Type]
3 : 2.5W DC Brushless motor
[Encoder Type]
I : Incremental
<I/O Type>
NP : NPN Type (Sync. Type) (Standard),
PN : PNP Type (Source Type),
PLN : Pulse Train Control NPN Type (Sync. Type),
PLP : Pulse Train Control PNP Type (Source Type),
DV : DeviceNet Connection Type, CC : CC-Link Connection Type,
PR : PROFIBUS-DP Connection Type, CN : CompoNet Connection Type,
ML : MECHATROLINK-Ⅰ/ⅡConnection Type, EC : EtherCAT Connection Type,
EP : EtherNet/IP Connection Type, PRT : PROFINET-IO Connection Type
<Identification for IAI use only>
* There is no identification in some cases.
<Type of Installation>
(Not Specified) : Screw Attachment Type
DN : DIN Rail Mounting Type
<Power-supply Voltage>
0 : 24V DC
<I/O Cable Length>
0 : Equipped with no cable
2 : 2m (Standard)
3 : 3m
5 : 5m
PROFINET-IO

ACON, DCON List of Specifications
Description
Item ACON-CA/CB/CGB DCON-CA/CB/CGB
Number of controlled axes 1-axis
Power-supply Voltage 24V DC ±10%
Series Motor Type Rated Max. Power
Consumption MAX.(Note5) Rated MAX.
2W 0.8A 4.6A
5W 1.0A 6.4A
10W (RCL) 1.3A 6.4A
10W (RCA/ RCA2) 1.3A 2.5A 4.4A
20W 1.3A 2.5A 4.4A
20W (Model: 20S) 1.7A 3.4A 5.1A
RCA,
RCA2,
RCL
30W 1.3A 2.2A 4.4A
Load
Capacity
(including
control side
current
consumption)
(Note1)
RCD 3W 0.7A 1.5A
Power Supply for Electromagnetic Brake
(for actuator equipped with brake) 24V DC ±10% 0.15A (MAX.)
Heat Generation 8.4W 4W
Rush Current (Note2) 10A
Transient Power Cutoff Durability MAX. 500μs
Motor Control System Sinusoidal Waveform (AC) Drive Rectangular Waveform (DC) Drive
Corresponding Encoder Incremental Encoder
Serial Absolute Encoder
Battery-less Absolute Encoder
Incremental Encoder
Incremental Type 800pulse/rev RCA
Serial Absolute Type 16384pulse/rev
RCA2_*** N 1048pulse/rev RCA2
Other than
RCA2_*** N 800pulse/rev
RCA
/RCA2
Battery-less
Absolute Type 16384pulse/rev
RA1, RA4, SA1, SA4 715pulse/rev
RA2, RA5, SA2, SA5 855pulse/rev
RCL
RA3, RA6, SA3, SA6 1145pulse/rev
Corresponding
Encoder
Resolution
RCD 400pulse/rev
Actuator Cable Length MAX. 20m
Serial Communication Interface
(SIO Port)
RS485 : 1 CH (based on Modbus Protocol RTU/ASCII)
Speed : 9.6 to 230.4Kbps
Control available with serial communication in the modes other than the pulse train
PIO Type Signal I/O dedicated for 24V DC (selected from NPN/PNP) … Input 16 points
max., output 16 points max. Cable length MAX. 10m
External Interface
Field Network Type DeviceNet, CC-Link, PROFIBUS-DP, CompoNet, MECHATROLINK,
EtherCAT, EtherNet/IP, PROFINET-IO
Data Setting and Input PC Software, Touch Panel Teaching, Teaching Pendant
Data Retention Memory Saves position data and parameters to non-volatile memory
(There is no limitation to the number of times data may be written.)
Operation Mode Positioner Mode/Pulse Train Control Mode (selected by parameter setting)
Number of Positions in Positioner Mode Standard 64 points, MAX. 512 points (PIO Type)
(Note) Number of positions differs depending on the selection in PIO pattern.
Differential System (Line Driver System) : MAX. 200kpps Cable length MAX. 10m Input Pulse Frequency
Open Collector System : Not applicable.
* If the host applies the open collector output, prepare AK-04 (option) separately
to convert to the differential type.
Command Pulse Multiplying
Factor (Electrical Gear : A/B)
1/50 < A/B < 50/1
Setting Range of A and B (set to parameter) : 1 to 4096
Pulse Train
Interface
(Note4)
Feedback Pulse Output None
LED Display
(mounted on Front Panel)
SV (GN)/ALM (RD) : Servo ON/Alarm generated
STS0 to 3 : Status display
RDY (GN)/ALM (RD) : Absolute function in normal / absolute function error (for the
simple absolute type)
1, 0 (GN) (RD) : Absolute function status display (for the simple absolute type)
Electromagnetic Brake Compulsory
Release Switch (mounted on Front Panel)
Switching NOM (standard)/BK RLS (compulsory release)
Insulation Resistance 500V DC 10MΩ or more
Protection Function against Electric Shock Class I basic insulation
Incremental Type Screw fixed type : 230g or less DIN rail fixed type : 265g or less
Simple Absolute Type Battery (AB-7) : 190g or less
Absolute Battery Case (SEP-ABU):
140g or less
Weight (Note3)
(Other than
Field
Network
Type) Serial Absolute Type Battery (AB-5) : 20g
Cooling Method Natural air-cooling
External dimensions Screw fixed type : 35W×178.5H×69.6D
DIN rail fixed type : 35W×185H×78.1D
Screw fixed type : 35W×190H×69.6D
DIN rail fixed type : 35W×196.3H×78.1D
Surrounding Air Temperature 0 to 40°C
Surrounding Humidity 85%RH or less (non-condensing)
Surrounding Environment [Refer to Installation Environment]
Surrounding Storage
Temperature
-20 to 70°C (Excluding battery)
Usage Altitude 1000m or less
Protection Class IP20
Environment
Vibration Durability Frequency 10 to 57Hz / Swing width : 0.075mm
Frequency 57 to 150Hz / Acceleration 9.8m/s2
XYZ directions Sweep time : 10 minutes Number of sweep : 10 times
Note1 Add an additional 0.3A inrush for Fieldbus Types.
Note2 In-rush current will flow for approximately 5msec after the power is turned on (at 40°C).
Note that the value of in-rush current differs depending on the impedance of the power supply line.
Note3 Add the weight of the battery (case) for “Simple Absolute Type” and “Serial Absolute Type”.
Note4 Serial absolute type is not applicable for the pulse train control mode.
Note5 The current reaches the maximum at the excitation phase detection of the motor conducted when the servo is
turned on for the first time after the power is supplied. (TYP 1 to 2 second, MAX. 10 second)
External Dimensions (All Types Except for PCON-CFA/CFB/CGFB)
● Screw fixed type
Incremental Type Simplified Absolute Type Serial Absolute Type Side View
(Option) (Option)
35
φ5
170.5 178.5
5
35
φ
5
5
(40.5)
(58)
170.5 178.5
69.9
Refer to
Basic Specification
35
φ
5
5
(34.5)
(52)
170.5 178.5
● DIN rail fixed type
Incremental Type Simplified Absolute Type Serial Absolute Type Side View
(Option) (Option)
35
178.5 185
(5)
M3
(for FG cable
attachment)
69.9
Refer to
Basic Specification
8.5
4
104 from DIN rail center
35.4 (Width of 35mm DIN rail)
M3
35
178.5
185
(5)
(58)
(for FG cable
attachment)
M3
35
178.5
185
(5)
(52)
(for FG cable
attachment)
External Dimensions (PCON-CFA/CFB/CGFB Type)
● Screw fixed type
35
(7)
170.5
190
5
φ
5
(Note1)
69.9
69.1
● DIN rail fixed
77.6
78.4
8.5
4
190
(5)
35
(7)
115 from DIN rail center
35.4 (Width of 35mm DIN rail)
Installation Environment
This product is capable for use in the environment of pollution degree 2*1 or equivalent.
*1 Pollution Degree 2: Environment that may cause non-conductive pollution or transient conductive
pollution by frost (IEC60664-1)
1. Installation Environment
Do not use this product in the following environment
• Location where the surrounding air temperature exceeds the range of 0 to 40°C
• Location where condensation occurs due to abrupt temperature changes
• Location where relative humidity exceeds 85%RH
• Location exposed to corrosive gases or combustible gases
• Location exposed to significant amount of dust, salt or iron powder
• Location subject to direct vibration or impact
• Location exposed to direct sunlight
• Location where the product may come in contact with water, oil or chemical droplets
• Environment that blocks the air vent [Refer to Installation and Noise Elimination]
When using the product in any of the locations specified below, provide a sufficient shield.
• Location subject to electrostatic noise
• Location where high electrical or magnetic field is present
• Location with the mains or power lines passing nearby
2. Storage and Preservation Environment
• Storage and preservation environment follows the installation environment. Especially in a long-term storage, consider
to avoid condensation of surrounding air.
Unless specially specified, moisture absorbency protection is not included in the package when the machine is
delivered. In the case that the machine is to be preserved in an environment where dew condensation is anticipated,
take the condensation preventive measures from outside of the entire package, or directly after opening the package.
Installation and Noise Elimination
1. Noise Elimination Grounding (Frame Ground)
2. Precautions regarding wiring method
1) Wire is to be twisted for the 24V DC power supply.
2) Separate the signal and encoder lines from the power
supply and power lines.
3. Noise Sources and Elimination
Carry out noise elimination measures for power devices on
the same power path and in the same equipment.
The following are examples of measures to eliminate noise
sources.
1) AC solenoid valves, magnet switches and relays
[Measure] Install a Surge absorber parallel with the coil.
2) DC solenoid valves, magnet switches and relays
[Measure] Install a diode parallel with the coil. Use a DC
relay with a built-in diode.
Surge absorber
Relay
coil
Relay coil
R
C
+24V 0V
+24V 0V
+-
Do not share the ground wire with or connect
to other equipment. Ground each controller.
Controller
Other
equipment
Controller
Other
equipment
Other
equipment
Connect the ground cable
using the tapped hole for
FG connection on the main unit.
M3 × 5 nickeled pan head
machine screw
(enclosure dedicated for
DIN rail fixed type)
Screw fixed type DIN rail fixed type
Connect the ground line
together to the main unit
using the fixing screw.
Copper wire:
Connect a ground wire with a
diameter of 1.6mm (2mm
2
) or larger.
Earth Terminal
Grounding resistance 100Ω or less
(Class D grounding)

4. Heat Radiation and Installation
Design and Build the system considering the size of the controller box, location of the controller and
cooling factors to keep the surrounding temperature around the controller below 40°C.
Connection Diagram
● EtherCAT®
(Note 1) STP (with shield) is recommended for Ethernet cable.
(Note 2) It is necessary to prepare a power supply cable and the cables for the emergency stop circuit
wiring as well as this cable. [Refer to power supply and emergency stop circuit.]
● For EtherNet/IP and PROFINET-IO
(Note 1) STP (with shield) is recommended for Ethernet cable.
(Note 2) It is necessary to prepare a power supply cable and the cables for the emergency stop circuit
wiring as well as this cable. [Refer to power supply and emergency stop circuit.]
● Connection to RCP2 (High-Thrust), RCA and RCL Series
PCON
ACON
Motor/
Encoder Connector
Connection
Cable
(Note 1 )
● Connection to RCP3, RCP4, RCP5, RCP6 and RCA2 Series
Connection
Cable(Note
1 )
PCON
ACON
Motor/
Encoder Connector
● Connection to RCD Series
DCON
Connection
Cable
(Note 1 )
Motor/
Encoder Connector
Note 1 Applicable Connection Cable Model Codes □□□ : Cable Length Example) 030 = 3m
Model Name Cable Reference
RCP2 CB-PSEP-MPA□□□ Robot cable from 0.5 to 20m
CB-APSEP-MPA□□□ Robot cable from 0.5 to 20m
RCP3 CB-APSEP-MPA□□□-LC Standard cable from 0.5 to 20m
CB-CAN-MPA□□□-RB Robot cable from 0.5 to 20m
RCP4 (Other Than GR*Type)
RCD (Applicable Controller
Symbol : D3) CB-CAN-MPA□□□ Standard cable from 0.5 to 20m
CB-CAN-MPA□□□-RB Robot cable from 0.5 to 20m
RCP4 (GR*Type), RCP5
RCD (Applicable Controller
Symbol : D5) CB-CAN-MPA□□□ Standard cable from 0.5 to 20m
CB-CFA-MPA□□□ Standard cable for CFA type from 0.5 to 20m
High-Thrust CB-CFA-MPA□□□-RB Robot cable for CFA type from 0.5 to 20m
RCA, RCL (Incremental Type) CB-ASEP-MPA□□□
CB-ASEP2-MPA□□□ Robot cable from 0.5 to 20m
RCA (Serial Absolute Type)
RCA2 CB-APSEP-MPA□□□ Robot cable from 0.5 to 20m
Power Supply and Emergency Stop Circuit
This shows the circuit example when the emergency stop switch in the teaching pendant is enabled on the
emergency stop circuit to be built up by the client.
In the example below, uses PCON-CA. It is the same in case of except for PCON-CA.
Note 1 : The safety categories complied type (CGB Type, etc.) is not equipped with the relay to have the controller
automatically identify that a teaching tool was plugged in and switch the wiring layout. Those other than the safety
categories complied type do the automatic identification and have S1 and S2 short-circuited.
Note 2 : When the motor driving source is cut off externally for a compliance with the safety category, connect a contact
such as a contactor to the wires between MPI and MPO. Also, the ratings for the emergency stop signal that turns
ON/OFF at the contact CR1 are 24V DC and 10mA or less.
Note 3 : For CR1, select the one with coil current 0.1A or less.
Caution If supplying power with using a 24V DC, having it turned ON/OFF, keep the 0V connected and have the
+24V supplied/cut (cut one side only).
[Reference] Example for operating an actuator by using the standard type (CA or CB Type) with optimum
wiring layout
(Note) In this example, the emergency stop switch on the teaching pendant would not work.
Operation Modes and Functions (Common to Each Fieldbus)
The machine can be operated selecting one mode from the following five operation modes.
(1) Remote I/O Mode : This is the method where the operation through PIO (24V I/O) is performed using the fieldbus.
(2) Position/ : This is the method where the machine is operated by means of directly specifying the target
Simple Direct position using numerical values.
Value Mode For the speed, acceleration, deceleration, or positioning width, the already registered position
data values are used.
(3) Half Direct Value Mode : In this operation mode, in addition to the target position, the speed, acceleration, deceleration
and push current value are directly specified using numerical values.
(4) Full Direct Value Mode : In this operation mode, all the values related to the position control, are directly specified using
numerical values.
(5) Remote I/O Mode 2 : Additionally, the current position and current speed reading functions are added to the remote I/O
mode.
Operation Modes and Main Functions
Main Functions Remote I/O
Mode
Position/
Simple Direct
Value Mode
Half Direct
Value Mode
Full Direct Value
Mode
Remote I/O
Mode 2
No. of Occupied Bytes 2 8 16 32 12
Operation with the Position No.
Specified { { ¯ ¯ {
Operation with the Position Data
Specified ¯ { (Note) { { ¯
Speed and Acceleration Direct Setup ¯ ¯ { { ¯
Pressing Operation { { { { {
Current Position Read ¯ { { { {
Current Speed Read ¯ ¯ { { {
Completion Position No. Read { { ¯ ¯ {
Max. Number of position table 512 768 Unused Unused 512
(Note) The actuator is operated by specifying all position data, other than the position, using a position number.
EtherCAT®
● Specification
Item Specification
Communication Protocol IEC61158Type12
Physical Layer 100BASE-TX (IEEE802.3)
Communication Frequency Automatic following to the Master
Communication Cable Length Depends on EtherCAT® Type (Distance between each node: 100m max.)
Slave Type I/O slave
Applicable Node Address 0 to 127
(17 to 80 : When connected to the master (CJ1W-NC*81) manufactured by OMRON)
Communication Cable Category 5e or more
(Double shielded cable braided with aluminum foil recommended)
Connector RJ45 Connector × 2pcs (Input × 1, Output × 1)
Connection Daisy chain only
● Interface Section
(Note) Refer to the troubleshooting or the Instruction Manual for the details of LED displays.
MIN.
30mm
MIN.
30mm
MIN.
30mm
MIN.
30mm
MIN. 100mm
MIN. 50mm
MIN. 100mm
Ensure enough space
for wiring.
Status Display LED
Status LED (RUN/ERR)
EtherCAT® Output Port
Link/Activity LED (Output)
EtherCAT® Input Port
Link/Activity LED (Input)
Host System (PLC) Ethernet Straight Cable
(Note 1)
(general-purpose cable, Category 5e or more)
Status Display LED
Status LED
Brake Release
Switch
PC Software
(Option)
Power Supply Terminal
(Note 2)
Actuator Actuator
I/O Slave, etc.
Axis No.
Setting Switch
Operation Mode
Setting Switch
Touch Panel Teaching
(Option)
Hub
Actuator Actuator
Host System (PLC)
Ethernet
Straight Cable
(Note 1)
Ethernet
Straight Cable
(Note 1)
Status Display LED
Status LED (general-purpose cable,
Category 5e or more)
I/O Slave, etc.
Power Supply Terminal
(Note 2)
PC Software
(Option)
Brake Release
Switch
Axis No. Setting Switch
Operation Mode
Setting Switch
Touch Panel Teaching
(Option)
S1
S2
MPI
MPO
24V
0V
24V
0V
EMG-
BKLS
Power Supply
Connector
Emergency-stop
Switch on the
Teaching Pendant
Control
Power
Supply
SIO Connector
Wiring Condected
at Delivery
24V DC
Power Supply
Motor Power Supply
Emergency Stop Control Circuit
Brake Release Power Supply
(Note) Supply 24V when connecting actuator
equipped with brake and release brake
compulsorily
Emergency
-stop Switch
24V 0V
0V
Emergency
Stop Reset
Switch
Emergency
Stop Switch
CR1
S1
S2
MPI
MPO
24V
EMG-
BKLS
CR1
(Note 3)
Brake Forced
Release Switch
Power Supply
Connector
PCON-CA
Emergency-stop
Switch on the
Teaching Pendant
Control
Power
Supply
SIO Connector
(Note 1)
Motor Power Supply
CR2
(Note 2)
Emergency Stop Control Circuit
Brake Release Power Supply
(Note) Supply 24V when connecting actuator
equipped with brake and release brake
compulsorily

● EtherCAT® Connector
Pin No. Signal Name Abbreviated Code
1 Data sending + TD+
2 Data sending - TD−
3 Data receiving + RD+
4 Not used
5 Not used
6 Data receiving - RD−
7 Not used
8 Not used
Connector Hood Security grounding FG
● Operation Mode Setting and Address Allocation
The operation mode is set using the parameters.
Set the mode change switch on the controller front panel to “MANU” side and set the parameter No.84
“FMOD: Fieldbbus Operation Mode” using the teaching tool such as PC software for RC.
[Refer to the Instruction Manual for the details]
● Node address setting
Node address can be set with the parameter.
Set Parameter No.85 “NADR: Fieldbus Node Address” with a teaching tool such as PC software for RC.
Settable Range: 0 to 127 (It is set to 17 which is the I/O slave top address of EtherCAT® at the delivery.)
● Communication Speed Setting
The setting for the communication speed is not required because it automatically follows the master’s
communication speed.
(Note) After parameter setting, reset the controller mode change witch to “AUTO” side, and then cycle the controller power.
EtherNet/IP
● Specification
Item Specification
Communication Protocol IEC61158 (IEEE802.3)
Communication Speed 10BASE-T/100BASE-T (Autonegotiation setting is recommended)
Communication Cable Length Depends on EtherNet/IP Type
(Distance between hub and each node: 100m max.)
Number of Connection Depends on the master unit
Applicable Node Address 0.0.0.0 to 255.255.255.255
Communication Cable Category 5 or more
(Double shielded cable braided with aluminum foil recommended)
Connector RJ45 Connector × 1pc
● Interface Section
(Note) Refer to the troubleshooting or the Instruction Manual for the details of LED displays.
● EtherNet/IP Connector
Pin No. Signal Name Abbreviated Code
1 Data sending + TD+
2 Data sending - TD−
3 Data receiving + RD+
4 Not used
5 Not used
6 Data receiving - RD−
7 Not used
8 Not used
Connector Hood Security grounding FG
● Operation Mode Setting and Address Allocation
The operation mode is set using the parameters.
Set the mode change switch on the controller front panel to “MANU” side and set the parameter No.84
“FMOD: Fieldbus Operation Mode” using the teaching tool such as PC software for RC.
[Refer to the Instruction Manual for the details]
● Communication Speed Setting
The Communication speed can be set with the parameter. A special setting is not necessary since it is set
to automatic negotiation when the product is delivered. However, when a fixed speed is required, change
the setting to the desired speed in Parameter No.86 “FBRS: Fieldbus Communication Speed” of the
teaching tool in the PC software for RC.
[Refer to the Instruction Manual for the details]
● IP Address Setting
IP Address can be set with the parameter.
Set Parameter No.140 “IPAD: IP Address” with a teaching tool such as PC software for RC.
Settable Range: 0.0.0.0 to 255.255.255.255 (It is set to “192.168.0.1” when the machine is delivered from
the factory.)
● Settings for Subnet Mask
Subnet Mask can be set with the parameter.
Set Parameter No.141 “SNMK: Subnet Mask” with a teaching tool such as PC software for RC.
Settable Range: 0.0.0.0 to 255.255.255.255 (It is set to “255.255.255.0” when the machine is delivered
from the factory.)
● Settings for Default Gateway
Default Gateway can be set with the parameter.
Set Parameter No.142 “DFGW: Default Gateway” with a teaching tool such as PC software for RC.
Settable Range: 0.0.0.0 to 255.255.255.255 (It is set to “0.0.0.0” when the machine is delivered from the
factory.)
(Note) After parameter setting, reset the controller mode change witch to “AUTO” side, and then cycle the controller power.
PROFINET-IO
● Specification
Item Specification
Communication protocol IEC61158 (IEEE802.3), IEC61748
Communication Speed 100Mbps
Communication cable length Depends on PROFINET-IO Specification
(Distance between each segment: 100m Max.)
Number of Connection Depends on the master unit
Applicable node address 0.0.0.0 to 255.255.255.255
Communication cable Category 5 or more
(Double shielded cable braided with aluminum foil recommended)
Connector RJ45 Connector × 1pc
● Interface Section
(Note) Refer to the troubleshooting or the Instruction Manual for the details of LED displays.
● EherNet/IP Connector
Pin No. Signal Name Abbreviated Code
1 Data sending + TD+
2 Data sending − TD−
3 Data receiving + RD+
4 Not used
5 Not used
6 Data receiving − RD−
7 Not used
8 Not used
Connector Hood Security grounding FG
● Operation Mode Setting and Address Allocation
The operation mode is set using the parameters.
Set the mode change switch on the controller front panel to “MANU” side and set the parameter No. 84
“FMOD: Field Bus Operation Mode” using the teaching tool such as PC software for RC.
[Refer to the Instruction Manual for the details]
● Communication Speed Setting
It is not necessary to establish setting. It is fixed at 100Mbps.
● Node address setting
It is not necessary to establish setting on the IAI controller side as it should be established on the master
side.
(Note) After parameter setting, reset the controller mode change witch to “AUTO” side, and then cycle the controller power.
Starting Procedure
When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to
the procedure below.
This section explains how to start up an EtherCAT®, EtherNet/IP and PROFINET-IO complaint PCON,
ACON and DCON (described as the “controller” in the following diagram). For the settings and wiring of each
of the individual devices, controllers, and actuators connected to the network, refer to the individual device’s
Instruction Manual.
Trouble Shooting
If an error has occurred, it is possible to check the operation condition on the status LEDs on the front panel.
● Status LED Displays of EtherCAT® Type { : Illuminating, × : OFF, ☆ : Flashing
Name Indication Color Description
× Initial condition (EtherCAT® communication in “INIT” condition) or the
power is OFF
{ (GN) In normal operation (EtherCAT® communication in “OPERATION”
condition)
☆ (GN)
(ON: 200ms/OFF: 200ms) (EtherCAT® communication in “PRE-OPERATION” condition)
☆ (GN)
(ON: 200ms/OFF: 1000ms) (EtherCAT® communication in “SAFE-OPERATION” condition)
RUN
{ (OR) Communication component (module) error
× No abnormality or the power is OFF
☆ (OR)
(ON: 200ms/OFF: 200ms)
Construction information (settings) error
(Information received from the master cannot be set)
☆ (OR)
(ON: 200ms × 2 times/
OFF: 1000ms)
Communication section circuit error
(Watchdog timer timeout)
ERR
{ (OR) Communication component (module) error
× Link status not detected or the power is OFF
{ (GN) Linked (No network congestion)
Link/
Activity ☆ (GN)
(ON: 50ms/OFF: 50ms) Linked (Network in congestion)
1
8
RJ45 8-pin
Modular Connector
(Controller side)
1
8
RJ45 8-pin
Modular Connector
(Controller side)
NS LED
MS LED
EtherNet/IP Port
Status LED
Status Diplay LED
Check of Packed Items
Has everything been received?
Installation and Wiring
Follow Instruction Manual and this manual to install the
controller and connect to the network.
Also, perform the wirings of the motor and encoder
cables for the power supply unit and the actuators
following the Instruction Manual of each controller.
To turn ON the controller
1) Set the mode switch on the front panel to MANU side.
2) Set the brake release switch on the front panel to NOM side.
3) Connect a teaching tool such as the PC software.
4) Turn the power ON and start up the teaching tool with
“Teaching Mode Safety Speed Valid” setting.
Controller Initial Settings
Refer to each fieldbus section to perform the necessary parameter settings of the modes, addresses, etc.
• Set Parameter No.35 Safety Speed if necessary. [Initial Value: 100mm/s]
Servo ON
Turn the servo ON by operating the teaching tool.
Contact us or our distributor.
Point Check Item
• Is frame ground (FG) connected?
• Has the noise countermeasure been taken?
Important Check Item
Is the status display LED on
the front panel turned OFF?
Check the detail of the alarm on
the teaching tool and remedy
any errors.
Yes↓
No↓
→
→
No→
↓Yes
←Yes
↓
↓
Note (In the case that the actuator is in vertical mount)
When the machine is turned ON/OFF repeatedly at the same
position, the actuator position may lower slightly due to its own
weight. Take care not to catch your hand or damage the work.
Check of Safety Circuit
Check that the emergency stop circuit (or motor drive-power cutoff circuit)
operates normally to turn OFF the servo.
Important Check Item
Is the status display LED
turned ON in green?
If an alarm is generated (status display
LED is ON in red), check the detail of
the alarm on the teaching tool and
remedy any errors.
Settings on Host System
Refer to PLC Instruction Manual to perform the communication settings and so on.
Refer to the Instruction Manual
for each unit, controller and PLC
to check each setting.
No↓
Yes↓
↓Yes
↓
↓
→
No→
Communication is now established. Perform an operation check and adjustment for the system.
Confirming Communication Establishment
• Confirm the communication is established on the status LED on the front
panel. [Refer to the troubleshooting]
• Is the LED status in normal condition? Is PLC (master unit) side also
in normal condition?
(Note) Refer to PLC and master unit Instruction Manuals for how to check
the master unit side.
1
8
RJ45 8-pin
Modular Connector
(Controller Side)
PROFINET-IO Port
NS
MS
Monitoring LED
SV/ALM Status Display LED

● Status LED Displays of EtherNet/IP Type { : Illuminating, × : OFF, ☆ : Flashing
Name Indication Color Description
× Power is OFF or IP addresses are not set
{ (GN) Connection is established and the communication under normal condition.
☆ (GN) Online but network connection is not yet established. Communication Stop (Network
is normal). Check the conditions of master unit.
{ (RD)
Communication Error. Communication
cannot be established due to the error
detection such as IP address duplication.
NS
☆ (RD) Communication Error. (Communication
Time-out Detection)
Check the conditions of IP address
settings, communication line, the power
of hub units, noise prevention, etc.
× Power OFF
{ (GN) The machine is in the normal operation.
The machine is under the control of the scanner (master)
☆ (GN)
The connection with the scanner (master) is not established.
Check the construction information settings.
Check if the scanner (master) is in the idle condition.
{ (RD) Hardware Error.
The replacement of the board is required. Please contact us.
MS
☆ (RD)
There is an error occurred but is not critical such like a user setting error or
configuration error.
It can be recovered with a rebuild of the settings.
● Status LED Displays of PROFINET-IO Type { : Illuminating, × : OFF, ☆ : Flashing
Name Indication Color Description
× The power is OFF or there is no connectable controller.
{ (GN) Connection is established, communication in normal condition (RUN status)
NS
☆ (GN) Connection is established, but communication in pause (STOP status: network is in
normal condition)
× Power OFF
{ (GN) The machine is in the normal operation.
☆ (GN) In diagnosis of communication system.
{ (OR) There is a hardware error (in EXCEPTION condition).
The replacement of the board is required. Please contact us.
MS
☆ (RD) There is an error in communication setting, IP address or station name setting.
When an error occurs, connect the teaching tool such as PC software or teaching pendant and check it
using the status monitor.
All the alarms for the fieldbus related are described as follows. For other alarms, refer to the instruction
manual for the controller body and remedy it.
Code Error Name ID
(*1) RES (*2) Cause/Treatment
0F2 Fieldbus
Module Error 05 × Cause : An error is detected on Fieldbus module (circuit component)
Treatment : Check the parameter.
0F3
Undetected
Fieldbus
Module Error
04 ×
Cause : Fieldbus module (circuit component) cannot be detected
Treatment : Turn ON the power again. If the error is not removed, contact
our company.
(*1) ID → Simple Alarm Code
(*2) RES → Alarm Reset Available/Unavailable ○ : Alarm Reset Available/× : Alarm Reset Unavailable
Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan
TEL [phone] FAX [phone]
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TEL [phone] FAX [phone]
SHANGHAI JIAHUA BUSINESS CENTER A8-303, 808, Hongqiao Rd. Shanghai 200030, China
TEL [phone] FAX [phone]
website: www.iai-robot.com
Technical Support available in USA, Europe and China
Head Office: 2690 W. 237th Street, Torrance, CA 90505
TEL [phone] FAX [phone]
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TEL[phone] FAX [phone]
TEL [phone] FAX [phone]
website: www.intelligentactuator.com
Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066
825 PhairojKijja Tower 12th Floor, Bangna-Trad RD., Bangna, Bangna, Bangkok 10260, Thailand
TEL [phone] FAX [phone]
Manual No.: ME0304-6C