IAI ERC3 User manual

IAI Corporation
ERC3 Gateway Unit
Instruction Manual Forth Edition

Please Read Before Use
Thank you for purchasing our product.
This Instruction Manual describes all necessary information items to operate this product safely
such as the operation procedure, structure and maintenance procedure.
To ensure the safe operation of this product, please read and fully understand this manual.
The enclosed CD or DVD in this product package includes the Instruction Manual for this product.
For the operation of this product, print out the necessary sections in the Instruction Manual or
display them using the personal computer.
After reading through this manual, keep this Instruction Manual at hand so that the operator of this
product can read it whenever necessary.
[Important]
•This Instruction Manual is original.
•The product cannot be operated in any way unless expressly specified in this Instruction
Manual. IAI shall assume no responsibility for the outcome of any operation not specified
herein.
•Information contained in this Instruction 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 Instruction Manual without permission is prohibited.
•The company names, names of products and trademarks of each company shown in the
sentences are registered trademarks.
•DeviceNet is a registered mark of ODVA.
•CC-Link is a registered mark of Mitsubishi Electric Corporation.
•PROFIBUS is a registered mark of SIEMENS.
•CompoNet is a registered trademark of OMRON Corporation.
•MECHATROLINK is a registered trademark of MECHATROLINK Members Association.
•EtherCAT® is a registered mark of Beckoff Automation GmbH.
•EtherNet/IP is a trademark used under the license of ODVA.
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Table of Contents
Safety Guide ·····················································································································1
Precautions in Operation ··································································································8
International Standards Compliances ·············································································10
Name for Each Parts and Their Functions······································································ 11
ERC3 Axes ·····················································································································17
Starting Procedures ········································································································18
Chapter 1 Specifications Check······················································································19
1.1 Product Check ············································································································ 19
1.1.1 Parts····················································································································· 19
1.1.2 Teaching Tool······································································································· 19
1.1.3 Instruction Manuals Related to this Product, which are Contained in the
Instruction Manual (DVD). ··················································································· 20
1.1.4 How to Read the Model Plate·············································································· 20
1.1.5 How to Read the Model ······················································································· 20
1.2 Basic Specifications ···································································································· 21
1.3 Calculation for Power Capacity··················································································· 22
1.4 Specifications for each Fieldbus ················································································· 23
1.4.1 Specifications of DeviceNet Interface ·································································· 23
1.4.2 Specifications of CC-Link Interface······································································ 23
1.4.3 Specifications of PROFIBUS-DP Interface ·························································· 24
1.4.4 Specifications of CompoNet Interface ································································· 24
1.4.5 Specifications of MECHATROLINK-I/II Interface················································· 24
1.4.6 Specifications of EtherNet/IP Interface ································································ 25
1.4.7 Specifications of EtherCAT Interface ··································································· 25
1.5 External Dimensions ··································································································· 26
1.6 Option ························································································································· 27
1.7 Installation and Storage Environment ········································································· 28
1.8 Noise Elimination and Mounting Method ···································································· 29
Chapter 2 Wiring························································································································· 31
2.1 Wiring Diagram (Connection of Construction Devices) ·············································· 31
2.2 Circuit Diagram ··········································································································· 32
2.3 Wiring Method············································································································· 37
2.3.1 Connection to Power Input Connector································································· 37
2.3.2 Connection with ERC3 Actuators ········································································ 38
2.3.3 Connection to Battery Connector ········································································ 39
2.3.4 Connection of SIO Connector·············································································· 40
2.3.5 Wiring Layout of Fieldbus Connector ·································································· 41
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Chapter 3 Operation ·······································································································47
3.1 Basic Operation ·········································································································· 47
3.1.1 Basic Operation Methods ···················································································· 47
3.1.2 Parameter Settings ······························································································ 50
3.2 Initial Setting ··············································································································· 51
3.3 Setting of Position Data ······························································································ 56
3.3.1 CON Mode Type Setting······················································································ 56
3.3.2 Settings for MEC Mode Type··············································································· 61
3.4 Field Network Address Map························································································ 65
3.4.1 PLC Address Construction by each Operation Mode·········································· 65
3.4.2 Example for each Field Network Address Map ··················································· 67
3.4.3 Gateway Control Signals (in common for all operation modes) ·························· 76
3.4.4 Control Signals for Positioner 1/Simple Direct Mode ·········································· 79
3.4.5 Control Signals for Direct Indication Mode ·························································· 84
3.4.6 Control Signals for Positioner 2 Mode ································································· 91
3.4.7 Control Signals for Positioner 3 Mode ································································· 95
3.4.8 Control Signals for Remote I/O Mode·································································· 98
3.4.9 About Commands (Position Data Read/Write and Alarm Axis Read) ··············· 104
3.5 Input and Output Signal Process for Field Network·················································· 119
3.6 I/O Signal Controls and Function·············································································· 121
3.7 About Gateway Parameter Setting Tool···································································· 135
3.7.1 Startup of Tool···································································································· 135
3.7.2 Explanation of each Menu ················································································· 136
3.7.3 Description of Functions ···················································································· 138
3.7.4 Operation Mode Setting····················································································· 144
3.8 Field Network LED Indication ··················································································· 145
Chapter 4 I/O Parameter ····························································································151
Chapter 5 Troubleshooting·························································································153
5.1 Action to Be Taken upon Occurrence of Problem····················································· 153
5.2 Fault Diagnosis ········································································································· 154
5.2.1 Impossible Operation of Controller ···································································· 154
5.2.2 Positioning and Speed of Poor Precision (Incorrect Operation)························ 155
5.2.3 Generation of Noise and/or Vibration ································································ 156
5.2.4 Communication Not Established········································································ 156
5.3 Alarm Level ··············································································································· 157
5.4 Alarm List ·················································································································· 158
5.4.1 Gateway Alarm Codes ······················································································· 158
5.4.2 Simple Alarm Code ···························································································· 160
5.4.3 Alarm Codes for ERC3 (Each Axis)··································································· 161
Chapter 6 Appendix····································································································169
6.1 Specifications of Actuator·························································································· 169
6.1.1 In the case of high output setting valid for Slider Type (Screw Cover Type) ····· 169
6.1.2 In the case of high output setting invalid for Slider Type (Screw Cover Type) ·· 170
6.1.3 In the case of high output setting valid for Slider Type (Stainless Steel Sheet
Type / Cleanroom Type) ···················································································· 171
6.1.4 In the case of high output setting invalid for Slider Type (Stainless Steel
Sheet Type / Cleanroom Type)·········································································· 172
6.1.5 In the case of high output setting valid for Rod Type ········································ 173
6.1.6 In the case of high output setting invalid for Rod Type······································ 173
6.1.7 Pressing Force and Current Limit Value···························································· 174
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Chapter 7 Warranty ····································································································175
7.1 Warranty Period ········································································································ 175
7.2 Scope of Warranty ···································································································· 175
7.3 Honoring the Warranty······························································································ 175
7.4 Limited Liability ········································································································· 175
7.5 Conditions of Conformance with Applicable Standards/Regulations,
Etc., and Applications································································································ 176
7.6 Other Items Excluded from Warranty········································································ 176
Change History·············································································································177
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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.
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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 instruction 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
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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 100 or below).
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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.
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5
No. Operation
Description Description
6 Trial
Operation
● When the work is carried out with 2 or more persons, make it clear who
is to be the leader and who to be the follower(s) and communicate well
with each other to ensure the safety of the workers.
● After the teaching or programming operation, perform the check
operation one step by one step and then shift to the automatic
operation.
● When 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.
● Make 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.
● Do 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
● Check before starting the automatic operation or rebooting after
operation stop that there is nobody in the safety protection fence.
● Before starting automatic operation, make sure that all peripheral
equipment is in an automatic-operation-ready state and there is no
alarm indication.
● Make sure to operate automatic operation start from outside of the
safety protection fence.
● In 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.
● When 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.
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6
No. Operation
Description Description
8 Maintenance
and
Inspection
● 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 work out of 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 work is to be performed inside the safety protection fence,
basically turn OFF the power switch.
● 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.
● For the grease for the guide or ball screw, use appropriate grease
according to the Instruction Manual for each model.
● Do not perform the dielectric strength test. Failure to do so may result in
a damage to the product.
● 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.
● The 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.
● Pay 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.
Use in incomplete condition may cause damage to the product or an
injury.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.
9 Modification
and Dismantle
● Do not modify, disassemble, assemble or use of maintenance parts not
specified based at your own discretion.
10 Disposal ● When the product becomes no longer usable or necessary, dispose of it
properly as an industrial waste.
● When removing the actuator for disposal, pay attention to drop of
components when detaching screws.
● Do not put the product in a fire when disposing of it.
The product may burst or generate toxic gases.
11 Other ● Do 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.
● See Overseas Specifications Compliance Manual to check whether
complies if necessary.
● For the handling of actuators and controllers, follow the dedicated
instruction manual of each unit to ensure the safety.
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Alert Indication
The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the
warning level, as follows, and described in the Instruction Manual for each model.
Level Degree of Danger and Damage Symbol
Danger
This indicates an imminently hazardous situation which, if the
product is not handled correctly, will result in death or serious
injury. Danger
Warning
This indicates a potentially hazardous situation which, if the
product is not handled correctly, could result in death or serious
injury. Warning
Caution
This indicates a potentially hazardous situation which, if the
product is not handled correctly, may result in minor injury or
property damage. Caution
Notice This indicates lower possibility for the injury, but should be kept to
use this product properly. Notice
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Precautions in Operation
1. Make sure to follow the usage condition, environment and specification range
of the product.
In case it is not secured, it may cause a drop in performance or malfunction of the product.
2. This can be used by connecting to ERC3 Serial Communication Type (CON
Mode Type or MEC Mode Type).
It is not applicable for any others but the serial communication type.
It cannot be connected with CON Mode and MEC Mode together.
3. Use an appropriate teaching tool.
Use the PC Software for an appropriate teaching pendant to interface with this controller.
[Refer to 1.1.2 Teaching Tool]
4. Set the operation patterns.
This unit is applicable for various types of Fieldbus and possesses multiple operation patterns.
Set an appropriate operation pattern considering the control method to be used. [Refer to
Chapter 3. Operation and Chapter 4 I/O Parameters.]
Warning : Please note it is very risky when the control sequence and operation pattern
setting do not match each other. The normal operation might not occur. There may
be no movement, or there may be unexpected movement.
5. Operation cannot be performed unless there is an input of Servo-ON Signal.
The servo-ON signal (SON) is available to select whether to enable or disable in the initial
setting process “Servo Control”.
If it is set to “Enable”, the ERC3 would not operate unless turning this signal ON.
If parameter No.21 is set to “Not to use”, SON is disabled. If it is set to “Disable”, the servo turns
ON and the actuator operation becomes enabled as soon as the power supply to the controller
is turned ON and the emergency stop signal is cancelled.
Have the setting that suits to the desirable control logic.
6. Clock Setting in Calendar Function
There may be a case in the first time to supply the power after delivery that Gateway Error
Code 4A “Real Time Clock Vibration Stop Detected” is generated. In the case this happens, set
the current time with a teaching tool.
If the battery is fully charged, the clock data is retained for approximately 10 days after the
power is turned OFF.
Even though the time setting is conducted before the product is shipped, the battery is not fully
charged. Therefore, there may be a case that the clock data is lost even if the days described
above have not passed.
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7. According to Sequence Program Creation
Please note the following things when creating a sequence program.
When data transfer is necessary between two devices that have a different scan time from
each other, duration more than the longer scan time is required to certainly read the signal. (It
is recommended to have a timer setting of at least twice as long as the scan time in order for
the PLC to adequately perform the reading process.)
● Operation Image
Also, if one tries to read the signal that is being re-written by the other, the signal may be read wrong.
Make sure to read the signal after the rewriting is complete. (It is recommended to have more than 2 scan
periods to wait.) Make sure not to have the output side to change the output until the other side completes
the reading. Also, a setting is made on the input area not to receive the signal less than a certain time to
prevent a wrong reading of noise. This duration also needs to be considered.
8. PLC Timer Setting
Do not have the PLC timer setting to be done with the minimum setting.
Setting to “1” for 100msec timer turns ON at the timing from 0 to 100msec while 10msec timer
from 0 to 10msec for some PLC.
Therefore, the same process as when the timer is not set is held and may cause a failure such
as the actuator cannot get positioned to the indicated position number in Positioner Mode.
Set “2” as the minimum value for the setting of 10msec timer and when setting to 100msec, use
10msec timer and set to “10”.
This controller
(scan time 1msec)
PLC
(e.g. scan time is 20msec)
Output
Process
Input
Process
As shown in the diagram, the input and output
timings of two devices that have different scan
time do not match, when transferring a signal.
There is no guarantee that PLC would read the
signal as soon as this controller signal turns ON.
In such a case, make the setting to read the
signal after a certain time that is longer than the
longer scan time to ensure the reading process
succeeds on the PLC side.
It is the same in the case this controller side
reads the signal.
In such a case, it is recommended to ensure 2 to
4 times of the scan time for the timer setting
margin.
It is risky to have the setting below the scan time
since the timer is also processed in the scan
process.
In the diagram, PLC can only read the input once
in 20msec even though this controller output
once in 1msec.
Because PLC only conducts output process once
in 20msec, this controller identifies the same
output status for that entire time period.
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International Standards Compliances
ERC3 Gateway Unit with the following overseas standard.
RoHS Directive CE Marking UL
 To be scheduled To be scheduled
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Name for Each Parts and Their Functions
 Front
4th Axis (AX3)
3rd Axis (AX2)
1st Axis (AX0)
2nd Axis (AX1)
5) Operation Mode Setting Switch
7) Gateway Status LED
4) SIO Connector
3) Absolute Battery Connector
2) Power Connector
1) FG Terminal Block
6) Axis Status LED 8) Position Adjustment
Switch
1st Axis (AX0)
1st Axis (AX0) 9
)
Brake Release Switch
4th Axis (AX3)
3rd Axis (AX2)
2nd Axis (AX1)
2nd Axis (AX1)
3rd Axis (AX2)
4th Axis (AX3)
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 Upper surfaces
 Bottom surfaces
1st Axis (AX0)
10) Field Network Connection Connector
11) ERC3 Connection
Connector
2nd Axis (AX0)
3rd Axis (AX0)
4th Axis (AX0)
ME0302-4A