IAI ROBO Cylinder RCP2 Series User manual

ROBO Cylinder
RCP2/RCP2W Actuator
Rod Type
Operation Manual
Fourteenth Edition
IAI America, Inc.
Motor straight types
Standard types
RCP2- RA2CRA3C
RA4CRA6CRA8C
RA10CRGS4CRGS6C
RGD3CRGD4CRGD6C
Dustproof/Splash proof type Motor straight types RCP2W-RA4CRA6CRA10C
Motor reversing types RCP2- RA3RRA4RRA6RRA8R

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 ofany 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 contentof thismanual,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.

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
Precautions in Handling...................................................................................................8
Names of the Parts........................................................................................................ 11
1. Product Check .........................................................................................................21
1.1 Parts.........................................................................................................................................21
1.2 Operation Manuals for Controllers Supported by This Product................................................22
1.3 How to read the model plate ....................................................................................................22
1.4 How to read the model No. ......................................................................................................23
1.4.1 RCP2..........................................................................................................................23
2. Specications ..........................................................................................................24
3. Product Life .............................................................................................................39
3.1 RCP2/RCP2W Rod Type for other than RCP2-RA8C, RA8R, RA10C and RCP2W-RA10C ..39
3.2 RCP2-RA8C, RA8R .................................................................................................................39
3.3 RCP2-RA10C, RCP2W-RA10C ...............................................................................................40
4. Installation Environment, Storage and Preservation Environment ..........................41
4.1 Installation Environment...........................................................................................................41
4.2 Storage and Preservation Environment ...................................................................................41
5. Installation ...............................................................................................................42
5.1 Installing the Main Body ...........................................................................................................42
6. Connection the controller......................................................................................... 53
6.1 Wiring .......................................................................................................................................53
7. Cautions in Operation.............................................................................................. 56
7.1 Load on the Actuator ................................................................................................................56
7.2 Caution for when setting to 60% or more of RCP2-RA8 pressing current limit value ..............57
8. Option ......................................................................................................................62
8.1 Brake........................................................................................................................................62
8.2 Flange Bracket .........................................................................................................................63
8.3 Foot Bracket.............................................................................................................................64
8.4 Single Guide.............................................................................................................................66
8.5 ReversedHomeSpecication..................................................................................................66
8.6 Connector cable exit direction changed ...................................................................................66
9. Motor•EncoderCables........................................................................................... 67
9.1 Cable for PMEC and PSEP Controllers ...................................................................................67
9.2 Cable for PCON and PSEL Controllers....................................................................................68
10. Maintenance ............................................................................................................70
10.1 Maintenance Schedule.............................................................................................................70
10.2 Visual Inspection of the Machine Exterior ................................................................................70
10.3 Cleaning ...................................................................................................................................70

10.4 Applying Grease to the Ball Screw and Rod Slide Surface......................................................71
10.4.1 Grease for Ball Screw ................................................................................................71
10.4.2 How to Apply Grease (Keep the spraying time to within 1 second per spray.)...........71
10.5 Grease Supply to Scraper........................................................................................................73
10.5.1 Grease .......................................................................................................................73
10.5.2 Grease Supply ...........................................................................................................73
11. Belt Replacement and Adjustment ..........................................................................74
11.1 Belt Inspection..........................................................................................................................74
11.2 Belts to be used .......................................................................................................................74
11.3 Replacement Belt.....................................................................................................................75
12. Process for Motor Replacement.............................................................................. 77
12.1 Process to replace motor for RA8C and RA8R........................................................................77
12.1.1 Process to replace motor for RA8C ...........................................................................77
12.1.2 Process to replace motor for RA8R ...........................................................................82
12.2 Process to replace motor for RA10C .......................................................................................87
13. Appendix..................................................................................................................92
13.1 External Dimensions ................................................................................................................92
13.1.1 RCP2-RA2C...............................................................................................................92
13.1.2 RCP2-RA3C...............................................................................................................93
13.1.3 RCP2-RA4C...............................................................................................................94
13.1.4 RCP2-RA6C...............................................................................................................95
13.1.5 RCP2-RA8C...............................................................................................................96
13.1.6 RCP2-RA10C.............................................................................................................97
13.1.7 RCP2-RA3R...............................................................................................................98
13.1.8 RCP2-RA4R...............................................................................................................99
13.1.9 RCP2-RA6R.............................................................................................................100
13.1.10 RCP2-RA8R.............................................................................................................101
13.1.11 RCP2-RGS4C ..........................................................................................................102
13.1.12 RCP2-RGS6C ..........................................................................................................103
13.1.13 RCP2-RGD3C..........................................................................................................104
13.1.14 RCP2-RGD4C..........................................................................................................105
13.1.15 RCP2-RGD6C..........................................................................................................106
13.1.16 RCP2W-RA4C .........................................................................................................107
13.1.17 RCP2W-RA6C .........................................................................................................108
13.1.18 RCP2W-RA10C .......................................................................................................109
14. Warranty ................................................................................................................ 110
14.1 Warranty Period ..................................................................................................................... 110
14.2 Scope of Warranty.................................................................................................................. 110
14.3 Honoring the Warranty ........................................................................................................... 110
14.4 Limited Liability....................................................................................................................... 110
14.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications . 111
14.6 Other Items Excluded from Warranty ..................................................................................... 111
Cange History.............................................................................................................. 112

1
1
Safety Guide
“Safety Guide” has been written to use the machine safely and so prevent personal injury or
property damage beforehand. Make sure to read it before the operation of this product.
Safety Precautions for Our Products
The common safety precautions for the use of any of our robots in each operation.
No. Operation
Description Description
1 Model
Selection
●This product has not been planned and designed for the application
where high level of safety is required, so the guarantee of the protection
of human life is impossible. Accordingly, do not use it in any of the
following applications.
1) Medical equipment used to maintain, control or otherwise affect
human life or physical health.
2) Mechanisms and machinery designed for the purpose of moving or
transporting people (For vehicle, railway facility or air navigation
facility)
3) Important safety parts of machinery (Safety device, etc.)
●Do not use the product outside the specifications. Failure to do so may
considerably shorten the life of the product.
●Do not use it in any of the following environments.
1) Location where there is any inflammable gas, inflammable object or
explosive
2) Place with potential exposure to radiation
3) Location with the ambient temperature or relative humidity exceeding
the specification range
4) Location where radiant heat is added from direct sunlight or other
large heat source
5) Location where condensation occurs due to abrupt temperature
changes
6) Location where there is any corrosive gas (sulfuric acid or
hydrochloric acid)
7) Location exposed to significant amount of dust, salt or iron powder
8) Location subject to direct vibration or impact
●For an actuator used in vertical orientation, select a model which is
equipped with a brake. If selecting a model with no brake, the moving
part may drop when the power is turned OFF and may cause an
accident such as an injury or damage on the work piece.

2
2
No. Operation
Description Description
2 Transportation ●When carrying a heavy object, do the work with two or more persons or
utilize equipment such as crane.
●When the work is carried out with 2 or more persons, make it clear who
is to be the leader and who to be the follower(s) and communicate well
with each other to ensure the safety of the workers.
●When 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.
●Transport 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 operation manual for each model.
●Do not step or sit on the package.
●Do not put any heavy thing that can deform the package, on it.
●When using a crane capable of 1t or more of weight, have an operator
who has qualifications for crane operation and sling work.
●When using a crane or equivalent equipments, make sure not to hang a
load that weighs more than the equipment’s capability limit.
●Use a hook that is suitable for the load. Consider the safety factor of the
hook in such factors as shear strength.
●Do not get on the load that is hung on a crane.
●Do not leave a load hung up with a crane.
●Do not stand under the load that is hung up with a crane.
3 Storage and
Preservation
●The storage and preservation environment conforms to the installation
environment. However, especially give consideration to the prevention
of condensation.
●Store 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.
●Make 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.
●Do 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.
●When 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
3
No. Operation
Description Description
(2) Cable Wiring
●Use our company’s genuine cables for connecting between the actuator
and controller, and for the teaching tool.
●Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do
not coil it around. 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.
●Perform the wiring for the product, after turning OFF the power to the
unit, so that there is no wiring error.
●When 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.
●Connect 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.
●Never 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
●The grounding operation should be performed to prevent an electric
shock or electrostatic charge, enhance the noise-resistance ability and
control the unnecessary electromagnetic radiation.
●For 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).
●Perform Class D Grounding (former Class 3 Grounding with ground
resistance 100Ωor below).

4
4
No. Operation
Description Description
4 Installation
and Start
(4) Safety Measures
●When the work is carried out with 2 or more persons, make it clear who
is to be the leader and who to be the follower(s) and communicate well
with each other to ensure the safety of the workers.
●When the product is under operation or in the ready mode, take the
safety measures (such as the installation of safety and protection
fence) so that nobody can enter the area within the robot’s movable
range. When the robot under operation is touched, it may result in
death or serious injury.
●Make sure to install the emergency stop circuit so that the unit can be
stopped immediately in an emergency during the unit operation.
●Take the safety measure not to start up the unit only with the power
turning ON. Failure to do so may start up the machine suddenly and
cause an injury or damage to the product.
●Take the safety measure not to start up the machine only with the
emergency stop cancellation or recovery after the power failure. Failure
to do so may result in an electric shock or injury due to unexpected
power input.
●When the installation or adjustment operation is to be performed, give
clear warnings such as “Under Operation; Do not turn ON the power!”
etc. Sudden power input may cause an electric shock or injury.
●Take the measure so that the work part is not dropped in power failure
or emergency stop.
●Wear protection gloves, goggle or safety shoes, as necessary, to
secure safety.
●Do not insert a finger or object in the openings in the product. Failure to
do so may cause an injury, electric shock, damage to the product or
fire.
●When 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.
5 Teaching ●When the work is carried out with 2 or more persons, make it clear who
is to be the leader and who to be the follower(s) and communicate well
with each other to ensure the safety of the workers.
●Perform the teaching operation from outside the safety protection
fence, if possible. In the case that the operation is to be performed
unavoidably inside the safety protection fence, prepare the “Stipulations
for the Operation” and make sure that all the workers acknowledge and
understand them well.
●When 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.
●When 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.
●Place a sign “Under Operation” at the position easy to see.
●When 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.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.