IAI PCON-CY User manual

Operation Manual Ninth Edition
PCON-CY Controller
Solenoid Valve Type
Fifteenth Edition

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 CD or 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. Use Environment
PCON controllers can be used in an environment corresponding to pollution degree 2 or equivalent.
2. PC Software and Teaching Pendant Models
New functions have been added to the entire PCON controller series.
To support these new features, the communication protocol has been changed to the general Modbus
(Modbus-compliant) mode. As a result, the existing PC software programs and teaching pendants compatible
with RCP2 controllers can no longer be used.
If you are using this controller, use a compatible PC software program and/or teaching pendant selected from the
following models.
skrameRledoM
PC software (with RS232C
communication cable) RCM-101-MW
PC software (with USB communication
cable) RCM-101-USB
Teaching pendant RCM-T
Simple teaching pendant RCM-E
Data setting unit RCM-P
All are compatible with existing RCP2
controllers.
3. Recommendation for Backing Up Latest Data
This product uses nonvolatile memory to store the position table and parameters. Normally the memory will retain
the stored data even after the power is disconnected. However, the data may be lost if the nonvolatile memory
becomes faulty.
We strongly recommend that the latest position table and parameter data be backed up so that the data can be
restored quickly when the controller must be replaced for a given reason.
The data can be backed up using the following methods:
[1] Save to a CD or FD from the PC software.
[2] Create a position table sheet or parameter sheet and keep a written record of backup.

4. Using Rotary Actuators in Multi-rotation Specification
Rotary actuators of multi-rotation specification models can be set to operate in the multi-rotation mode or
limited-rotation mode using a parameter.
4.1 Note
Pay attention to the PIO pattern parameter setting for the following controllers.
Each controller does not support relative coordinate specification in the PIO pattern specified below:
[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25)
[2] PCON-CY: PIO pattern = 0 (User parameter No. 25)
4.2 Applicable Models
*-IP82-C-NOCP*-063-02-P82-I-LBTR-2PCR
*-IP82-GC-NOCP*-063-03-P82-I-LBTR-2PCR
*-IP82-YC-NOCP*-063-02-P82-I-LCTR-2PCR
Actuators
RCP2-RTCL-I-28P-30-360-*
Controllers
PCON-SE-28PI-*
CAUTION

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 Differences from Air Cylinders in Control Functions.....................................................................................10
1.3 How to Read Model Name ...........................................................................................................................12
1.4 System Configuration...................................................................................................................................13
1.5 Steps from Unpacking to Adjustment by Trial Operation..............................................................................14
1.6 Warranty.......................................................................................................................................................16
2. Specifications.................................................................................................................................18
2.1 Basic Specifications .....................................................................................................................................18
2.2 Name and Function of Each Part of the Controller.......................................................................................19
2.3 External Dimensions ....................................................................................................................................20
3. Installation and Wiring....................................................................................................................21
3.1 Installation Environment...............................................................................................................................21
3.2 Supplied Voltage..........................................................................................................................................21
3.3 Noise Elimination Measures and Grounding ................................................................................................22
3.4 Heat Radiation and Installation ....................................................................................................................23
3.5 External Connection Diagram ......................................................................................................................24
3.6 Wiring the Power Supply..............................................................................................................................25
3.7 Wiring the Brake Forced-release Switch ......................................................................................................25
3.8 Wiring the Emergency Stop Circuit ..............................................................................................................26
3.8.1 Cutting Off the Drive Signal (Standard) ............................................................................................26
3.8.2 Cutting Off the Motor Drive Power ....................................................................................................28
1.6.1 Warranty Period................................................................................................................................ 16
1.6.2 Scope of Warranty............................................................................................................................ 16
1.6.3 Honoring the Warranty...................................................................................................................... 16
1.6.4 Limited Liability..................................................................................................................................16
1.6.5 Conditions of Conformance with Applicable Standards/Regulations, Etc.,
and Applications................................................................................................................................ 17
1.6.6 Other Items Excluded from Warranty................................................................................................ 17
3.9 Connecting the Actuator...............................................................................................................................29
3.9.1 Motor Relay Cable ............................................................................................................................29
3.9.2 Encoder Relay Cable........................................................................................................................30
3.10 Connecting the I/O Flat Cable......................................................................................................................31
3.11 Connecting the Communication Cable.........................................................................................................32
4. Position Table Settings ..................................................................................................................33
4.1 Details of the Position Table ........................................................................................................................33
4.2 Notes on the ROBO Gripper ........................................................................................................................38
5. Operation Using I/O Signals ..........................................................................................................40
5.1 Interface Circuit............................................................................................................................................40
5.1.1 External Input Specifications.............................................................................................................40
5.1.2 External Output Specifications..........................................................................................................41
5.1.3 Recognition of Input Signals .............................................................................................................42
5.2 Proximity Switch Type..................................................................................................................................43
5.2.1 Explanation of I/O Signals.................................................................................................................43
5.2.2 Timings after Power On ....................................................................................................................45
Steps from Initial Startup to Actuator Adjustment........................................................................45
Normal Operating Procedure ......................................................................................................46

5.2.5 Positioning Operation .......................................................................................................................51
zMeaning of Position Detection Output Signals (LS0, LS1, LS2)..................................................52
zNotes on Setting the Positioning Band........................................................................................52
zSpeed Change during Movement................................................................................................53
zPausing during Movement...........................................................................................................54
zForced Return in Case of Emergency .........................................................................................54
5.3 Standard Type .............................................................................................................................................55
5.3.1 Explanation of I/O Signals.................................................................................................................55
5.3.2 Timings after Power On ....................................................................................................................57
zSteps from Initial Startup to Actuator Adjustment........................................................................57
zNormal Operating Procedure ......................................................................................................58
5.3.3 Position Table and Parameter Settings Required for Operation .......................................................60
Test Operation ............................................................................................................................60
Safety speed during manual feed .....................................................................................................60
Speed override for move commands from the PLC ..........................................................................60
Full-scale Operation ....................................................................................................................61
Power-saving when the standby time after power on is long ............................................................61
Power-saving when the standby time at the target position is long...................................................61
Complete signal output mode ...........................................................................................................61
5.3.4 Homing .............................................................................................................................................62
5.3.5 Positioning Operation .......................................................................................................................63
zMeaning of Positioning Complete Output Signals (PE0, PE1, PE2)............................................64
zNotes on Setting the Positioning Band........................................................................................64
zSpeed Change during Movement................................................................................................65
zPausing during Movement...........................................................................................................66
zForced Return in Case of Emergency .........................................................................................66
zConstant Pitch Feed....................................................................................................................67
5.3.6 Zone Output Signal...........................................................................................................................69
5.3.7 Push-motion Operation .....................................................................................................................70
5.3.8 Examples of Tact Time Reduction Combining Zone Outputs and 3 Stop Points ..............................76
5.4 Power-saving Modes at Standby Positions ..................................................................................................78
5.5 Using Rotary Actuators in Multi-rotation Specification..................................................................................81
5.5.1 How to Use .......................................................................................................................................81
6. Parameter Settings ........................................................................................................................82
6.1 Parameter List..............................................................................................................................................82
6.2 Detail Explanation of Parameters.................................................................................................................83
6.2.1 Parameters Relating to Actuator Stroke Range ................................................................................83
zSoft Limits (No.3/4 LIMM/LIML)...................................................................................................83
zHome Direction (No.5 ORG) .......................................................................................................83
zHome Offset (No.22 OFST).........................................................................................................84
zZone Limits (1: No. 1/2 ZONM/ZONL 2: No. 23/24 ZNM2/ZNL2)................................................84
6.2.2 Parameters Relating to Actuator Operating Characteristics..............................................................85
zDefault Speed (No.8 VCMD) .......................................................................................................85
zDefault Acceleration/Deceleration (No.9 ACMD).........................................................................85
zDefault Positioning Band (In-position) (No.10 INP) .....................................................................85
zCurrent-limiting Value during Homing (No.13 ODPW) ................................................................85
zCurrent-limiting Value at Standstill after Positioning (No.12 SPOW)...........................................85
zSpeed Override (No.46 OVRD)...................................................................................................85
zDefault Direction of Excited Phase Signal Detection (No.28 PHSP) ...........................................86
zExcited Phase Signal Detection Time (No.29 PHSP)..................................................................86
zAutomatic Servo-off Delay Time (No.36 ASO1/ No.37 ASO2/ No.38 ASO3) ..............................87
zDefault Standstill Mode (No.53 CTLF) ........................................................................................87
zPush Speed (No.34 PSHV) .........................................................................................................88
zPush-motion Completion Judgment Time (No.6 PSWT) .............................................................88
zEnable Function (No.42 FPIO) ....................................................................................................89
zHome Check Sensor Input Polarity (No.43 AIOF) .......................................................................89
zHome Sensor Input Polarity (No. 18, LS) ....................................................................................90
zBall Screw Lead (No. 77, LEAD) .................................................................................................90
zAxis Operation Type (No. 78, ATYP) ..........................................................................................90
zRotational Axis Mode Selection (No. 79, ATYP) .........................................................................90

Shortcut Selection for Rotational Axis (No. 80, ATYP)................................................................91
Absolute Unit (No. 83, ETYP)......................................................................................................91
6.2.3 Parameters Relating to External Interface ........................................................................................92
PIO Pattern Selection (No.25 IOPN) ...........................................................................................92
Positioning Complete Signal Output Mode (No.39FPIO) ............................................................92
Servo-on Input Disable Selection (No.21 FPIO)..........................................................................93
SIO Communication Speed (No.16 BRSL)..................................................................................93
Minimum Delay Time for Slave Transmitter Activation (No.17 RTIM) .........................................93
Silent Interval Multiplication Factor (No.45 SIVM) .......................................................................93
6.2.4 Servo Gain Adjustment .....................................................................................................................94
Servo Gain Number (No.7 PLG0) ...............................................................................................94
Speed Loop Proportional Gain (No.31 VLPG).............................................................................94
Speed Loop Integral Gain (No.32 VLPT) ....................................................................................95
Torque Filter Time Constant (No.33 TRQF)................................................................................95
7. Troubleshooting .............................................................................................................................96
7.1 What to Do When A Problem Occurs...........................................................................................................96
7.2 Alarm Level Classification ............................................................................................................................97
7.3 Alarms, Causes and Actions ........................................................................................................................98
(1) Operation Cancellation Alarms....................................................................................................98
(2) Cold Start Alarms ......................................................................................................................101
7.4 Messages Displayed during Teaching Pendant Operation ........................................................................104
7.5 Common Problems and Recommended Actions .......................................................................................106
I/O Signals Cannot Be Sent or Received to/from the PLC. .......................................................106
The ALM Lamp Illuminates after the Power Is Turned On.........................................................106
After Turning On the Power, the SV Lamp Does Not Illuminate upon Servo-on Signal Input....106
With an Actuator Installed in Vertical Orientation, Positioning Completes Prematurely. ...........107
With an Actuator Installed in Vertical Orientation, Noise Generates during Downward Movement.
107
Vibration Occurs when the Actuator Is at Standstill...................................................................107
The Actuator Overshoots while Decelerating to a Stop.............................................................107
Stopped Position Sometime Deviates from the Home Position or Target Position....................107
The Actuator Moves Slow during Push-motion Operation.........................................................107
The Actuator Moves Only a Half, or as Much as Twice, the Specified Travel. ..........................107
A Servo Error Occurred while the ROBO Gripper Was Moving.................................................108
The Actuator Malfunctions when the Servo Is Turned On after Turning On the Power.............109
The SV Lamp Blinks..................................................................................................................109
* Appendix...........................................................................................................................................110
List of Specifications of Connectable Actuators ....................................................................................................110
Correlation diagram of speed and load capacity for the slider type (motor-straight type) ...................................122
Correlation diagram of speed and load capacity for the slider type (motor-reversing type) ................................123
Correlation diagram of speed and load capacity for the standard rod type ...........................................................124
Correlation diagram of speed and load capacity for the single-guide type ............................................................125
Correlation diagram of speed and load capacity for the double-guide type...........................................................126
Correlation diagram of speed and load capacity for the dustproof/splash-proof type............................................127
Correlation diagram of speed and load capacity for the RCP3 slider type ............................................................128
Correlation diagram of speed and load capacity for the RCP3 table type .............................................................129
Push Force and Current-limiting Value..................................................................................................................130
Position Table Record ........................................................................................................................................... 137
Parameter
Change History
Record .................................................................................................................................................138
139......................................................................................................................................................
Push Speed (No.34 PSHV) .........................................................................................................88
Push-motion Completion Judgment Time (No.6 PSWT) .............................................................88
Enable Function (No.42 FPIO) ....................................................................................................89
Home Check Sensor Input Polarity (No.43 AIOF) .......................................................................89
Home Sensor Input Polarity (No. 18, LS) ....................................................................................90
Ball Screw Lead (No. 77, LEAD) .................................................................................................90
Axis Operation Type (No. 78, ATYP) ..........................................................................................90
Rotational Axis Mode Selection (No. 79, ATYP) .........................................................................90