RCS Series

ROBO Cylinder Controller

RCS-C Type
Operation Manual 18th Edition
 CAUTION

(1) Pause/servo ON signals

To operate the RCS (ROBO Cylinder), you must turn the PIO pause/servo ON
input signals to ON.

Take note that if the PIO pause input signal remains OFF, the RCS will remain
in pause and will not operate.

(2) The 100-V controller looks the same as the 200-V controller. However, the 100-
V controller will be damaged if 200 V is supplied. Pay due attention when
connecting the controller to a power source.

(3) Position 0 may be output regardless of the actual position. In the conditions
listed below, the position complete signal will turn ON no matter where the
actual position is. As a result, position 0 will be output.
1. When the power is turned on
2. When an emergency stop is cancelled
3. When an alarm is reset
4. When a reset is performed after a pause

Pay due attention when using position 0.

(4) With the absolute specification, an encoder reception error (0E5) will occur
when the power is turned on for the first time after the battery or PG cable was
disconnected. This does not indicate fault. If this error occurs, execute an
absolute reset by following the specified procedure.
Safety Precautions
Please read the information in “Safety Precautions” carefully before selecting a model and using the
product.
The precautions described below are designed to help you use the product safely and avoid bodily injury
and/or property damage.

Directions are classified as “danger,” “warning,” “caution” and “note,” according to the degree of
risk.

Failure to observe the instruction will result in an imminent danger leading to

Danger death or serious injury.

Warning Failure to observe the instruction may result in death or serious injury.

Caution Failure to observe the instruction may result in injury or property damage.

The user should take heed of this information to ensure the proper use of the
Note product, although failure to do so will not result in injury.

This product has been designed and manufactured as a component for use in general industrial
machinery.
Devices must be selected and handled by a system designer, personnel in charge of the actual operation
using the product or similar individual with sufficient knowledge and experience, who has read both the
catalog and operation manual (particularly the “Safety Precautions” section). Mishandling of the product
poses a risk.
Please read the operation manuals for all devices, including the main unit and controller.
It is the user’s responsibility to verify and determine the compatibility of this product with the user’s
system, and to use them properly.
After reading the catalog, operation manual and other materials, be sure to keep them in a convenient
place easily accessible to the personnel using this product.
When transferring or loaning this product to a third party, be sure to attach the catalog, operation manual
and other materials in a conspicuous location on the product, so that the new owner or user can
understand its safe and proper use.
The danger, warning and caution directions in this “Safety Precautions” do not cover every possible case.
Please read the catalog and operation manual for the given device, particularly for descriptions unique to
it, to ensure its safe and proper handling.

Danger
[General]
z Do not use this product for 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
3. Important safety parts of machinery
This product has not been planned or designed for applications requiring high levels of safety. Use of
this product in such applications may jeopardize the safety of human life. The warranty covers only the
product as it is delivered.
[Installation]
z Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The
product may ignite, burn or explode.
z Avoid using the product in a place where the main unit or controller may come in contact with water or
oil droplets.
z Never cut and/or reconnect the cables supplied with the product for the purpose of extending or
shortening the cable length. Doing so may result in fire.

[Operation]
z If you are using a pace maker or other mechanical implant, do not come within one meter of the
product. Doing so may cause the pace maker, etc., to malfunction due to the strong magnetic force
generated by the product.
z Do not pour water onto the product. Spraying water over the product, washing it with water or using it in
water may cause the product to malfunction, resulting in injury, electric shock, fire, etc.

[Maintenance, Inspection, Repair]

z Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in
injury, electric shock, fire, etc.
z Do not disassemble and reassemble the product. Doing so may result in injury, electric shock, fire, etc.

Warning
[General]
z Do not use the product outside the specifications. Using the product outside the specifications may
cause it to fail, stop functioning or sustain damage. It may also significantly reduce the service life of the
product. In particular, observe the maximum loading capacity and speed.

[Installation]
z If the machine will stop in the case of system problem such as emergency stop or power failure, design
a safety circuit or other device that will prevent equipment damage or injury.
z Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding:
Grounding resistance at 100 Ω or less). Leakage current may cause electric shock or malfunction.
z Before supplying power to and operating the product, always check the operation area of the equipment
to ensure safety. Supplying power to the product carelessly may cause electric shock or injury due to
contact with the moving parts.
z Wire the product correctly by referring to the operation manual. Securely connect the cables and
connectors so that they will not be disconnected or come loose. Failure to do so may cause the product
to malfunction or cause fire.

[Operation]
z Do not touch the terminal block or various switches while the power is supplied to the product. Failure to
observe this instruction may result in electric shock or malfunction.
z Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.),
confirm that the servo is turned off (using the teaching pendant). Failure to observe this instruction may
result in injury.
z The cables supplied with the product are flexible, but they are not robot cables. Do not store the cables
in a movable cable duct (cable bearer, etc.) that bends more than the specified bending radius.
z Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object or
pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock,
malfunction, etc.
z Turn off the power to the product in the event of power failure. Failure to do so may cause the product
to suddenly start moving when the power is restored, thus resulting in injury or product damage.
z If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing
to use the product may result in product damage or fire.
z If any of the internal protective devices (alarms) of the product has actuated, turn off the power
immediately. Continuing to use the product may result in product damage or injury due to malfunction.
Once the power supply is cut off, investigate and remove the cause and then turn on the power again.
z If the LEDs on the product do not illuminate after turning on the power, turn off the power immediately.
The protective device (fuse, etc.) on the live side may remain active. Request repair to the IAI sales
office from which you purchased the product.

[Maintenance, Inspection, Repair]

z Before conducting maintenance/inspection, parts replacement or other operations on the product,
completely shut down the power supply. At this time, take the following measures:
1. Display a sign that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER” at a conspicuous
place, in order to prevent a person other than the operator from accidentally turning on the power.
2. When two or more operators are to perform maintenance/inspection together, always call out every
time the power is turned on/off or an axis is moved in order to ensure safety.

[Disposal]
z Do not throw the product into fire. The product may burst or generate toxic gases.

Caution
[Installation]
z Do not use the product under direct sunlight (UV ray), in a place exposed to dust, salt or iron powder, in
a humid place, or in an atmosphere of organic solvent, phosphate-ester machine oil, etc. The product
may lose its function over a short period of time, or exhibit a sudden drop in performance or its service
life may be significantly reduced.
z Do not use the product in an atmosphere of corrosive gases (sulfuric acid or hydrochloric acid), etc.
Rust may form and reduce the structural strength.
z When using the product in any of the places specified below, provide a sufficient shield. Failure to do so
may result in malfunction:
1. Place where large current or high magnetic field is present
2. Place where welding or other operations are performed that cause arc discharge
3. Place subject to electrostatic noise
4. Place with potential exposure to radiation
z Install the main unit and controller in a place subject to as little dust as possible. Installing them in a
dusty place may result in malfunction.
z Do not install the product in a place subject to large vibration or impact (4.9 m/s2 or more). Doing so
may result in the malfunctioning of the product.
z Provide an emergency-stop device in a readily accessible position so the device can be actuated
immediately upon occurrence of a dangerous situation during operation. Lack of such device in an
appropriate position may result in injury.
z Provide sufficient maintenance space when installing the product. Routine inspection and maintenance
cannot be performed without sufficient space, which will eventually cause the equipment to stop or the
product to sustain damage.
z Do not hold the moving parts of the product or its cables during installation. It may result in injury.
z Always use IAI’s genuine cables for connection between the controller and the actuator. Also use IAI’s
genuine products for the key component units such as the actuator, controller and teaching pendant.
z Before installing or adjusting the product or performing other operations on the product, display a sign
that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER.” If the power is turned on
inadvertently, injury may result due to electric shock or sudden activation of an actuator.

[Operation]
z Turn on the power to individual equipment one by one, starting from the equipment at the highest level
in the system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or
product damage.
z Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.
z Do not bring a floppy disk or other magnetic data storage medium within one meter of the product. The
data inside the floppy disk, etc., may be damaged due to the magnetic force generated by the magnet
in the product.

[Maintenance, Inspection, Repair]

z Do not touch the terminals when performing an insulation resistance test. Electric shock may result. (Do
not perform any withstand voltage test on a product that uses DC power supply.)

Note
[General]
z If you are planning to use the product under a condition or environment not specified in the catalogs
and operation manual, or in an application requiring strict safety such as aircraft facility, combustion
system, entertainment machine, clean-room environment, safety device or other equipment having
significant impact on human life or property, design operating ranges with sufficient margins from the
ratings and design specifications or provide sufficient safety measures such as fail-safes. Whatever you
do, always consult IAI’s sales representative.

[Installation]
z Do not place objects around the controller that will block airflows. Insufficient ventilation may damage
the controller.
z Do not configure a control circuit that will cause the load to drop in case of power failure. Configure a
control circuit that will prevent the table or load from dropping when the power to the machine is cut off
or an emergency stop is actuated.

[Installation, Operation, Maintenance]

z When handling the product, wear protective gloves, protective goggles, safety shoes or other necessary
gear to ensure safety.

[Disposal]
z When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste.
z The backup battery uses a nickel-cadmium battery. Before disposing of the product, remove the nickel-
cadmium battery. Contact your nearest IAI sales office for a proper procedure to dispose of the
removed battery.

Others
„ IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the items
specified in “Safety Precautions.”
„ If you have any question regarding the product, please contact your nearest IAI sales office. The
addresses and phone numbers of our sales offices are provided at the end of this operation manual.
Before Use

„ Caution
[1] Be sure to read this operation manual to ensure the proper use of this product.
[2] Unauthorized use or reproduction of a part or all of this operation manual is prohibited.
[3] IAI shall not be liable whatsoever for any loss or damage arising from a handling or operation not
specified in this operation manual.
[4] The information contained in this operation manual is subject to change without notice.

„ Action to Be Taken in Case of Emergency

* If this product is found to be in a dangerous condition, immediately turn off all power switches of the main unit
and connected equipment or immediately disconnect all power cables from the outlets. (“Dangerous condition”
refers to a situation where the product is generating abnormal heat or smoke or has ignited and a fire or
danger to human health is anticipated.)
Table of Contents

1. Note to the User...................................................................................... 1

1-1 Introduction............................................................................................................................. 1
1-2 Safety Precautions ................................................................................................................. 2
1-3 Warranty Period and Scope of Warranty................................................................................ 3
1-4 Installation Environment and Noise Elimination ..................................................................... 4
1-5 Heat Radiation and Installation .............................................................................................. 7

2. 24-V Specification ................................................................................... 8

2-1 Connection Method ................................................................................................................ 8
2-2 External Dimensions ............................................................................................................ 10
2-3 24-V Controller ..................................................................................................................... 12
2-4 Names and Functions of Parts ............................................................................................. 13
2-5 Wiring ................................................................................................................................... 20

3. 100/200-V Specification ........................................................................ 27

3-1 Connection Method .............................................................................................................. 27
3-2 External Dimensions ............................................................................................................ 29
3-3 100/200-V Controller ............................................................................................................ 31
3-4 Names and Functions of Parts ............................................................................................. 32
3-5 Wiring ................................................................................................................................... 41

4. Data Entry <Basics> ............................................................................. 48

4-1 Description of Position-Data Table ....................................................................................... 49
4-2 Explanation of Modes........................................................................................................... 52

5. Using the Controller <Practical Steps> ................................................. 57

5-1 How to Start (Standard Type) ............................................................................................... 57
5-2 How to Execute Absolute Reset (Absolute Specification) .................................................... 58
5-3 Movement after Power On (Standard Type)......................................................................... 60
5-4 Positioning Mode (Back and Forth Movement between Two Points)................................... 62
5-5 Push & Hold Mode ............................................................................................................... 64
5-6 Speed Change during Movement......................................................................................... 66
5-7 Operation at Different Acceleration and Deceleration Settings............................................ 68
5-8 Pause ................................................................................................................................... 70
5-9 Zone Signal Output .............................................................................................................. 72
5-10 Returning Home ................................................................................................................... 74
5-11 Incremental Moves ............................................................................................................... 76
5-12 Notes on Incremental Mode ................................................................................................. 78

6. Parameter Table.................................................................................... 80
7. Alarm Table ........................................................................................... 81
* Appendix .................................................................................................. 86
Example of Basic RCS Positioning Sequence......................................................................................... 86
1. Note to the User
1-1 Introduction
Thank you for purchasing the RCS controller. This manual explains the features and operating procedures
of the product.

If not used or handled properly, any product cannot fully demonstrate its function or may cause an
unexpected breakdown or end its life prematurely. Please read this manual carefully and handle the
product with utmost care while ensuring its correct operation. Keep this manual in a convenient place so
the relevant sections can be referenced readily when necessary.

If you are also using any of IAI’s various actuators and/or optional PC software or teaching pendant, also
refer to the operation manual for each item.

Absolute Specification
• The absolute RCS controller is able to perform positioning operation immediately after the power has
been input and an absolute reset performed. You need not perform home return every time the
power is reconnected. Other basic functions are the same as those of the standard RCS controller.
• The absolute RCS controller is shipped without an absolute reset executed. It must be done by the
user.
Only RCS actuators of absolute specification can be used with the absolute RCS controller. It cannot
be used with RCS actuators of incremental specification.
• Notes on installing the absolute-data backup battery
Be sure to follow the installation steps below to initialize the battery circuit and thereby prevent an
early consumption of the battery:
[1] Connect the encoder cable.
[2] Turn on the power.
[3] Install the absolute-data backup battery.
The above steps must always be followed when the encoder cable has been disconnected for
relocation, etc.

• Actuator duty
It is recommended that IAI’s actuators be used at a duty of 50% or below as a guideline in view of the
relationship of service life and accuracy.
Duty is calculated by the formula below:

Operating hours
Duty (%) = x 100
Operating hours + Non - operating hours

1
• Controller version
A label on which a serial number is printed is attached on the right side of the controller.
The last two digits of the serial number, consisting of an alphabet and a number, indicate the version of
your controller.
Example) SERIAL No. ET352720 N5
In this example, the controller version is “N5.”
When the controller is updated to a higher version, the alphabet will change to a higher letter and the
number will increase. Take note that some controller specifications will vary depending on the version.

* We have made every effort to ensure accuracy of the information provided in this manual. Should you
find an error, however, or if you have any comment, please contact IAI.
Keep this manual in a convenient place so it can be referenced readily when necessary.

1-2 Safety Precautions

Read the following information carefully and provide safety measures with due consideration.

This system product has been developed as a drive component for automated machinery and the like, and
is therefore designed not to generate excessive torque or speed beyond the levels needed to drive
automated equipment. However, the following instructions must be strictly observed to prevent an
unexpected accident.

1. Do not handle this product in any manner not specified in this manual. If you have questions regarding
any of the information provided in this manual, please contact IAI.

2. Always use a genuine cable specified by IAI for connecting the actuator and RCS controller.

3. Do not enter the operating range of the machine while the machine is operating or is able to operate
(the controller power is ON). If the machine is used in a place accessible to other people, enclose its
operating range using a safety cage, etc.

4. Always turn off the power supply to the controller before assembling/adjusting or
maintaining/inspecting the machine. During assembly/adjustment or maintenance/inspection, put a
plate or other visible sign in a conspicuous place indicating that work is in progress. The operator
should keep the entire power cable beside him or her to prevent another person from inadvertently
plugging in the cable.

5. If two or more persons work together, set signaling methods so each person can confirm the safety of
other(s) during work. Especially when the work requires an axis or axes to be moved—with or without
the power and by motor drive or manual operation—the person moving each axis should always call
out beforehand to ensure safety.

6. If you have extended a cable or made other alteration to the standard wiring specification, thoroughly
check the wiring and ensure absence of problem before turning on the power, in order to prevent
malfunction due to miswiring.

2
1-3 Warranty Period and Scope of Warranty

The RCS controller you have purchased passed IAI’s shipping inspection implemented under the strictest
standards. The unit is covered by the following warranty:

1. Warranty Period

The warranty period shall be one of the following periods, whichever ends first:
• 18 months after shipment from our factory
• 12 months after delivery to a specified location

2. Scope of Warranty
If an obvious manufacturing defect is found during the above period under an appropriate condition of
use, IAI will repair the defect free of charge. Note, however, that the following items are excluded from
the scope of warranty:

• Aging such as natural discoloration of coating

• Wear of a consumable part due to use
• Noise or other sensory deviation that doesn’t affect the mechanical function
• Defect caused by inappropriate handling or use by the user
• Defect caused by inappropriate or erroneous maintenance/inspection
• Defect caused by use of a part other than IAI’s genuine part
• Defect caused by an alteration or other change not approved by IAI or its agent
• Defect caused by an act of God, accident, fire, etc.

The warranty covers only the product as it has been delivered and shall not cover any losses arising in
connection with the delivered product. The defective product must be brought to our factory for repair.

Please read carefully the above conditions of warranty.

3
1-4 Installation Environment and Noise Elimination

Pay due attention to the installation environment of the controller.

1-4-1 Installation Environment

(1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient
ventilation will not only prevent the controller from demonstrating its full performance, but it may also
cause breakdown.)
(2) Prevent foreign matter from entering the controller through the ventilation holes. Since the enclosure
of the controller is not dustproof or waterproof (oilproof), avoid using the controller in a place subject
to significant dust, oil mist or splashes of cutting fluid.
(3) Do not expose the controller to direct sunlight or radiating heat from a large heat source such as a
heat treatment furnace.
(4) Use the controller in an environment free from corrosive or inflammable gases, under a temperature
of 0 to 40°C and humidity of 85% or less (non-condensing).
(5) Use the controller in an environment where it will not receive any external vibration or shock.
(6) Prevent electrical noise from entering the controller or its cables.

1-4-2 Power Supply

The power supply specification is 24 VDC, 100 VAC or 200 VAC depending on the controller type.

1-4-3 Noise Elimination and Grounding

(1) Wiring and power supply

[1] 100/200-VAC controller

PE on the power terminal block is a protective grounding terminal. Provide Class D grounding.
Use a grounding cable of 0.75 mm2 (AWG18) or larger. The grounding cable must be longer than
the AC cable.

Class D grounding
(protective grounding)

100/200-VAC power supply

4
 [2] 24-VDC controller
The power terminal block does not have a protective grounding terminal, but the user must
separately provide a noise elimination measure and grounding.

(2) Grounding for noise elimination

Regardless of whether the power supply is 100/200 VAC or 24 VDC, the controller must always be
grounded to eliminate noise.

[1] Connect the controller by directly screwing it onto a metal frame.

100/200-V
controller 24-V
Protective grounding controller

(AC power supply)

(24 VDC)
[2] If the controller cannot
Use a cable of
a maximum
be screwed onto the
possible size frame, connect it to the
and keep the frame as shown in the
wiring distance figure at left.
at a minimum.

Metal frame

[3] Precautions regarding wiring method

Use a twisted cable for connection to the 24-VDC external power supply.
Separate the controller cables from high-power lines such as a cable connecting to a power circuit.
(Do not bundle together the controller cables with high-power lines or place them in the same cable
duct.)
When extending the supplied motor cable or encoder cable, consult IAI’s Technical Support.

5
(3) Noise sources and elimination
Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular
concern when building a system. Noise from these sources can be eliminated by implementing the
measures specified below.

[1] AC solenoid valves, magnet switches and relays

Measure: Install a surge absorber in parallel with the coil.

Å Point
Install a surge absorber to each coil over a minimum wiring length.
Installing a surge absorber to the terminal block or other part will
be less effective because of a longer distance from the coil.

The most effective method is to connect a surge absorber and a surge killer in parallel.

Surge absorber

Surge killer (CR set)

This way, noise will be eliminated in the entire range.

6
 [2] DC solenoid valves, magnet switches and relays

Measure: Install a diode in parallel with the coil. Determine the diode capacity in accordance with the
load capacity.

In a DC circuit, connecting a diode in reverse polarity will damage

the diode, internal parts of the controller and/or DC power supply,
so exercise due caution.

1-5 Heat Radiation and Installation

Design the control panel size, controller layout and cooling method in such a way that the temperature
around the controller will not exceed 40°C.

Install the controller vertically on a wall, as shown below. Since cooling is provided by way of natural
convection, always observe this installation direction and provide a minimum clearance of 50 mm above
and below the controller to ensure sufficient natural airflows.

When installing multiple controllers side by side, providing a ventilation fan or fans above the controllers
will help maintain a uniform temperature around the controllers.

Keep the front panel of the controller away from the wall (enclosure) by at least 100 mm.

Fan
50 mm or more
100 mm or
more

50 mm or more
Airflow

Regardless of whether your system consists of a single controller or multiple controllers, provide sufficient
clearances around each controller so that it can be installed/removed easily.

7
2. 24-V Specification
2-1 Connection Method
2-1-1 Standard Type

Teaching pendant
<RCA-T/TD>
Optional
Cable length: 5 m

ROBO Cylinder <RCS>

The cables are optional.

Host system <PLC>

Supplied flat
cable

External unit
<RCA-105-5>
Optional
Cable length: 5 m Cable length:
2m
PC

External unit
<RCA-105-5>
Optional
Cable length: 5 m

PC software
<RCA-101-MW> Do not insert/remove the
Optional connectors when the power
is on, except for the main
EMG switch communication port
24-VDC
power connector (PORT IN). To
supply insert/remove the PORT IN
connector, do so after turning
the PORT switch to OFF.

8
2-1-2 Absolute Specification

ROBO Cylinder <RCS>

The absolute specification
cannot be used with a
standard actuator.
The cables are optional.

Other connections are the same as those

of the standard type.

9
2-2 External Dimensions
2-2-1 Standard Type

10
2-2-2 Absolute Specification

11
2-3 24-V Controller

Item Specification
24-V type
Supply voltage 24 VDC ± 10%
Type RA35 RA45, F45 RB75 (30 W) RB75 (60 W) SA4, SA5 SA6
Supply current [A]
Rating Peak 1.8 4.3 2.4 6.0 2.3 4.6 3.9 7.5 1.2 3.7 1.4 3.9

Maximum motor output 60 W (Torque limit x 2) / Other (x 3)

Operating
0 to 40°C, 85%RH or less
temperature/humidity
Operating environment IP10, free from corrosive gases
Weight 540 g
Regenerative voltage error, motor overcurrent, power-stage overheat,
Protective functions
encoder error, motor overload, overspeed
LED indicators RDY (ready), RUN, ALM (alarm), ENC (encoder error)
DI/DO interface 24 VDC, insulated
Start
Command position number (4-bit binary)
8 dedicated
Pause
input ports
Reset
Servo ON
Completed position number (4-bit binary)
Input/output Position complete
Home return completion
10 dedicated Zone
output ports Alarm
Emergency stop
Moving
Serial interface input/output
Number of positions 16
Data entry method Teaching pendant, PC software
Storage device EEPROM 8 kbytes, S-RAM 128 kbytes

Note: Supplying the power-supply port or any I/O port with a voltage beyond the specified level may
result in controller failure.

12
 2-4 Names and Functions of Parts
2-4-1 Names

[1] Battery connector (BAT)

(absolute specification)
[9] LED indicators
[2] Motor connector (M)

[3] Brake release switch (BK) [10] Encoder/brake connector

(ENC)

[11] Piano switches 3

[4] SIO connector (SIO)
(SW3)
[5] Port switch (PORT) [12] Piano switches 2
(SW2)

[6] Main communication port connector [13] Piano switches 1

(PORT IN) (SW1)

[7] Regenerative resistor connector (RB) [14] PIO connector (PIO)

[8] Power/emergency-stop terminal block

2-4-2 Functions

[1] Battery connector

A connector for absolute-data backup battery (absolute specification).

[2] Motor connector (M)

A connector for the actuator’s motor power cable.

[3] Brake release switch (BK)

This switch is available only when the brake option is selected.
RLS: Brake is forcibly released
NOM: Brake is in use (Normal setting)

[4] SIO connector (SIO)

A connector for linking another controller when two or more controllers are connected.

13
[5] Port switch (PORT)
ON: The PORT IN port (teaching pendant/PC software) becomes active. If a dedicated teaching
pendant or cable is not connected to this port, the controller will recognize an emergency-
stop condition.
OFF: The PORT IN port (teaching pendant/PC software) becomes inactive. (Controller-to-
controller communication is possible.)

[6] Main communication port connector (PORT IN)

A connector for receiving the communication cable from a dedicated teaching pendant or external
equipment. It also receives a controller link cable when two or more axes are connected.

[7] Regenerative resistor connector (RB)

A connector for regenerative discharge resistor.
The controller will come with a regenerative resistor if the specified actuator capacity is 30 W or
above. However, connection is basically optional, and it should be connected when a regenerative
discharge error occurs. The error code of the regenerative discharge error is “0C9.”

[8] Power/emergency-stop terminal block

N: Connect the negative side of the 24-VDC power supply.
24V: Connect the positive side of the 24-VDC power supply.
EMG: Both terminals are used to connect an emergency-stop switch. (The controller is shipped
with the EMG terminals shorted.)

[9] LEDs
RDY: Indicate that the CPU is operating normally.
RUN: This LED turns on while the actuator is moving.
ENC: This LED turns on when the encoder cable is open or otherwise the encoder cannot be
recognized.
The LED also turns on when the voltage of the absolute-data backup battery drops.
ALM: This LED remains lit while an alarm is present.

[10] Encoder/brake connector (ENC)

A connector for encoder/brake power cable.

[11] Piano switches 3

Switches for selecting the encoder voltage. Use these switches if a custom cable is used and
possibility of voltage drop must be taken into consideration.
Set switches 1 and 2 to ON or OFF in accordance with the cable length.

1 2 Cable length
ON OFF 1∼5m
OFF ON 5 ∼ 10 m
ON ON 10 ∼ 15 m

Note: All piano switches are designated as Nos. 1, 2, etc., from the bottom.

[12] Piano switches 2

1 (bottom): ABS-CLR. Clear the absolute encoder data. Set this switch to ON when performing an
absolute reset. --- Normally OFF
2 (top): FWP. Write protect switch. Set this switch to ON when performing a remote upload.
--- Normally OFF

14
[13] Piano switches 1 (SW1)
Nos. 1 to 4 --- Address switches

Use these switches to set the address of the applicable actuator if two or more axes are connected
to the SIO connector. A desired address between 0 to 15 can be set.
(The factory setting is OFF for all of switch Nos. 1 to 4. This setting represents a condition where
only one axis is used.)
Use these switches to set a desired address for each controller. Make sure no address is duplicated
among the controllers. As long as they are unique, the addresses may not be contiguous and
missing numbers are allowed.

Piano switch numbers

Address
1 2 3 4
0 OFF OFF OFF OFF
1 ON OFF OFF OFF
2 OFF ON OFF OFF
3 ON ON OFF OFF
4 OFF OFF ON OFF
5 ON OFF ON OFF
6 OFF ON ON OFF
7 ON ON ON OFF
8 OFF OFF OFF ON
9 ON OFF OFF ON
10 OFF ON OFF ON
11 ON ON OFF ON
12 OFF OFF ON ON
13 ON OFF ON ON
14 OFF ON ON ON
15 ON ON ON ON

The controller link cable is 200

mm long.
A maximum of 16 controllers can
be connected.

Note: If multiple controllers are connected using link cables, the EMERGENCY STOP/ENABLE SW
on the teaching pendant (optional) becomes effective only with respect to the controller to
which the teaching pendant is connected.

[14] PIO connector (PIO)

A connector for PIO cable.

15
2-4-3 Pin Assignments of the Communication Ports

Pin assignments of the SIO connector

Pin No. Signal name Function
1 (+5V) (5-VDC power output) or (preliminary signal terminal)
2 SGA Positive logic side of the line transceiver I/O
3 GND Communication ground
4 SGB Negative logic side of the line transceiver I/O
5 GND Communication ground
6 (+5V) 5-VDC power output

Pin assignments of the main communication port

Pin No. Signal name Function
1 SGA Serial communication
2 SGB Serial communication
3 5V 5-V power output
4 EMGS Emergency-stop status
5 EMGA *1
6 24V 24-V power output
7 GND Ground
8 ENGB *1
*1 Used to actuate an emergency stop (contact b).
Short these pins to cancel an emergency stop.

2-4-4 Pin Assignments of Each Connector, and Terminal Block Specifications

Motor connector [Molex 5569-04A1]

Pin No. Signal name Connected wire
1 U Motor phase U
2 V Motor phase V
3 W Motor phase W
4 (NC)

16
Encoder/brake connector [High-density D-sub, DE-15 type]
Pin No. Signal name Connected wire
1 EN A+ Encoder A+
2 EN A– Encoder A-
3 EN B+ Encoder B+
4 EN B– Encoder B-
5 EN Z+ Encoder Z+
6 EN Z– Encoder Z-
7 SD+ Encoder SD+
8 SD– Encoder SD-
9 BAT+ (Battery+)
10 GND (Battery-)
11 EN 5 Encoder 5V+
12 EN GND Encoder COM-
13 BK N Brake-
14 BK P Brake+
15 FG Shield

Power/emergency-stop terminal block [Sato ML-800S IH (4P)]

Pin No. Signal name Connected wire
1 N (0V) Negative side of the 24-V power supply
2 24V Positive side of the 24-V power supply
3 EMG (24V) Emergency-stop switch (shorted before
4 EMG shipment)
Pin Nos. 2 and 3 are connected internally.

17
2-4-5 I/O Flat Cable
• Supplied with the Controller

I/O connector (40P)

Flat cable

I/O connector (40P)

No Signal name Color No Signal name Color No Signal name Color No Signal name Color
1 COM-OA Brown-1 11 NC Brown-2 21 COM-IA Brown-3 31 NC Brown-4
Position
2 COM-OA Red-1 12 Red-2 22 COM-IA Red-3 32 Start Red-4
complete
3 COM-OB Orange-1 13 NC Orange-2 23 COM-IB Orange-3 33 NC Orange-4
Completed Command
4 COM-OB Yellow-1 14 Yellow-2 24 COM-IB Yellow-3 34 Yellow-4
position 8 position 8
5 NC Green-1 15 NC Green-2 25 NC Green-3 35 NC Green-4
Completed Command
6 *Alarm Blue-1 16 Blue-2 26 *Pause Blue-3 36 Blue-4
position 4 position 4
7 NC Purple-1 17 Moving Purple-2 27 NC Purple-3 37 NC Purple-4
Completed Command
8 Zone Gray-1 18 Gray-2 28 Servo ON Gray-3 38 Gray-4
position 2 position 2
*Emergency
9 NC White-1 19 White-2 29 NC White-3 39 NC White-4
stop
Home return Completed Command
10 Black-1 20 Black-2 30 Reset Black-3 40 Black-4
completion position 1 position 1

• Optional

Output connector
(Split position)
I/O connector
Flat cable [A]

(Omron)
Input connector

[B]
(Omron)
(Omron)
[A] Output connector (20P) [B] Input connector (20P)
No Signal name Color No Signal name Color No Signal name Color No Signal name Color
1 COM-OA Brown-1 11 NC Brown-2 1 COM-IA Brown-1 11 NC Brown-2
2 COM-OA Red-1 12 Position complete Red-2 2 COM-IA Red-1 12 Start Red-2
3 COM-OB Orange-1 13 NC Orange-2 3 COM-IB Orange-1 13 NC Orange-2
Completed Command
4 COM-OB Yellow-1 14 Yellow-2 4 COM-IB Yellow-1 14 Yellow-2
position 8 position 8
5 NC Green-1 15 NC Green-2 5 NC Green-1 15 NC Green-2
Completed Command
6 *Alarm Blue-1 16 Blue-2 6 *Pause Blue-1 16 Blue-2
position 4 position 4
7 NC Purple-1 17 Moving Purple-2 7 NC Purple-1 17 NC Purple-2
Completed Command
8 Zone Gray-1 18 Gray-2 8 Servo ON Gray-1 18 Gray-2
position 2 position 2
9 NC White-1 19 *Emergency stop White-2 9 NC White-1 19 NC White-2
Home return Completed Command
10 Black-1 20 Black-2 10 Reset Black-1 20 Black-2
completion position 1 position 1
* The I/O connector (40P) is the same as the supplied connector described above.

18
2-4-6 Backup Battery (Absolute Specification)
(1) Battery specifications
Item Description
Model AB-1
Classification Lithium battery
Manufacturer Toshiba Battery (ER6VP)
Nominal voltage 3.6 V
Rated capacity 2000 mAh
Weight Approx. 8.5 g
Battery retention time Note 1) Approx. 20,000 hours (at ambient temperature of 20°C)

Note 1) The absolute-data backup battery consumers approx. 100 µA during backup. (When the main
controller power is on, the current consumption is approx. 4 µA.)
* Do not modify or extend the cable. It may result in controller failure.
* The battery is replaced together with the battery board. The battery cannot be replaced alone. Be sure
to use the battery module specified by IAI.
An absolute reset is required after the battery has been replaced.

19
2-5 Wiring
2-5-1 Wiring for Power Supply/Emergency Stop

Power/emergency-stop terminal block

* The two EMG terminals are contact-b inputs used for connecting an emergency-stop switch. The
controller is shipped with these terminals shorted, so that an emergency stop will not be actuated. 24
VDC is output to EMG of pin No. 3.
The current consumption of the emergency-stop circuit is approx. 35 mA (24-V controller).

Note: When performing power connection, make sure the following specifications for power cable, etc.,
are satisfied.

Single wire --- φ 1.0 (AWG18)

Applicable cable
Stranded wire --- 0.75 mm2 (AWG18)
Single wire --- φ 0.4 (AWG26) to φ 1.2 (AWG16)
Allowable wire size Stranded wire --- 0.3 mm2 (AWG22) to 1.25 mm2 (AWG16)
Element wire diameter --- φ 0.18 or larger
Standard stripped-wire length 11 mm
Button operation tool Flathead screwdriver (shaft diameter φ 3, blade tip width 2.6)

Note: This controller has no power switch.

20
2-5-2 External Connection Diagram

Brake
PC

Motor
connector
Teaching pendant
Conversion Encoder/brake
adapter connector
Main
communication port

Conversion adapter To the next controller

RS485
communication

Host
system
(PLC) Start
Command position 1
Output Command position 2
Command position 4
Command position 8
Pause
Reset
Servo ON

Completed position 1
Completed position 2

Input Completed position 4

Completed position 8
Position complete
Home return completion

Zone
Alarm
Moving
Emergency stop

External EMG button

Input voltage

21
2-5-3 PIO Interface
A PIO interface list is given below.
The PIO cable is a flat cable with no connector attached on the end connected to the external equipment.

PIO connector (40 pins)

Pin Reference Pin Reference
Category Signal name Cable color Category Signal name Cable color
No. No. No. No.
1 [1] COMOA Brown-1 2 [1] COMOA Red-1
3 [2] COMOB Orange-1 4 [2] COMOB Yellow-1
5 Green-1 6 [3] *Alarm Blue-1
7 Purple-1 8 [4] Zone Gray-1
Home return
9 White-1 10 [5] Black-1
completion
NC Position
11 Brown-2 12 [6] Red-2
complete
Output Output Completed
13 Orange-2 14 Yellow-2
position 8
Completed
15 Green-2 16 Blue-2
position 4
[7]
Completed
17 [8] Moving Purple-2 18 Gray-2
position 2
*Emergency Completed
19 [9] White-2 20 Black-2
stop position 1
21 [10] COMIA Brown-3 22 [10] COMIA Red-3
23 [11] COMIB Orange-3 24 [11] COMIB Yellow-3
25 Green-3 26 [12] *Pause Blue-3
27 Purple-3 28 [13] Servo ON Gray-3
29 White-3 30 [14] Reset Black-3
31 Brown-4 32 [15] Start Red-4
Input NC Input Command
33 Orange-4 34 Yellow-4
position 8
Command
35 Green-4 36 Blue-4
position 4
[16]
Command
37 Purple-4 38 Gray-4
position 2
Command
39 White-4 40 Black-4
position 1

Note: The ports indicated by an asterisk (*) conform to the contact-b signal logic (always ON).
Never connect those ports that are not used.

22
[1] COMOA
Power supply for output ports
[2] COMOB
Connect the 24-VDC power supply for output ports between COMOA and COMOB.
COMOA and COMOB have no polarities.
Pin Nos. 1 & 2, and 3 & 4 are connected internally.
[3] Alarm
This signal will turn OFF when an alarm occurs. It remains ON as long as the controller is operating
properly.
To reset an alarm, remove the cause of the alarm, and then input a reset signal or reconnect the
power.
[4] Zone
A zone signal will be output when the actuator enters the range set by the applicable parameter.
[5] Home return completion
This signal will turn ON when the initial home return is completed after a power connection.
Thereafter, this signal will remain ON until the power is turned off. It will not turn OFF following an
emergency-stop signal input.
If the home return completion signal is OFF, it means home return will be performed before the next
movement operation.

Note: With the absolute specification, the home return completion signal will turn ON when the power
is turned on, after an absolute reset was executed once. If the home return completion signal
turns OFF due to an alarm, an absolute reset must be executed again.

[6] Position complete

This signal will turn ON when the controller becomes ready following a power connection. It will turn
OFF when a start signal is input, and turn ON when a movement is completed.
[7] Completed position
All completed position signals will turn OFF the moment the position complete signal turns OFF.
All completed position signals remain OFF while an emergency stop is actuated or during the direct
teaching mode.
When the controller returns to the ready mode thereafter, the completed position signal
corresponding to the current actuator position will be output if the current actuator position is within
the positioning band from the last position complete position. If the current actuator position is outside
the positioning band, all completed position signals will remain OFF.
In the push & hold mode, all completed position signals will remain OFF when the controller returns
to the ready mode from an emergency-stop status or the direct teaching mode, regardless of the
current actuator position.
[8] Moving
This signal remains ON while the actuator is moving.
Use this signal if you want to detect stopping of the motor during pause.

23
[9] Emergency stop
This signal will turn OFF when an emergency stop is actuated. It remains ON as long as the
controller is operating properly.
When the emergency stop is cancelled, the signal will turn ON.
[10] COMIA
Power supply for input ports
[11] COMIB
Connect the 24-VDC power supply for input ports between COMIA and COMIB.
Pin Nos. 21 & 22, and 23 & 24 are connected internally.
[12] Pause
This is a contact-b input. Keep the signal ON while the actuator is moving, and cause it to turn OFF
when the movement pauses.
[13] Servo ON
The servo is ON while this signal is ON.
[14] Reset
An alarm will be reset once a rise of this signal is detected. If the cause of the alarm is not yet
removed, the alarm will come back after the reset action. (Only the overcurrent alarm (alarm code:
0C8) requires a power reconnection.)
When this signal is input while the actuator is in pause, the remaining travel will be cancelled.
[15] Start
Inputting this signal will start movement.
[16] Command position
Input the position number you want to select.
Relationship of input pin numbers and selected position numbers (4-bit binary)

One of 16 positions from 0 to 15 can be input/selected.

1: ON 0: OFF

40 Command position 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
38 Command position 2 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1
Pin No.
36 Command position 4 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
34 Command position 8 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
Selected position No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Note: The actuator will not operate if the start input is turned ON after selecting a position number for
which no position data is entered. (A bank 31 error (alarm code: 0B1) will occur.)

24
 2-5-4 24-V External I/O Specifications
Input Part
Item Specification
Number of input points 8 points
Input voltage 24 VDC ± 20 %
Input current 7 mA per circuit
ON voltage --- 16 V min. (4.5 mA)
Operating voltage
OFF voltage --- 6 V max. (1.4 mA)
Insulation method Photocoupler

Internal circuit configuration (Standard NPN specification)

Pin No.
External
power supply
24 VDC Rectifier

Internal circuit
Each input

• Connect a 24-V power supply between COMIA and COMIB.

• Connect the input common to the negative side of the external power supply.
• Pin Nos. 21 and 22 of COMIA and 23 and 24 of COMIB are connected internally.

Internal circuit configuration (Optional PNP specification)

Each input
Internal circuit

Pin No.

External
power supply Rectifier
24 VDC

• Connect a 24-V power supply between COMIA and COMIB.

• Connect the input common to the positive side of the external power supply.
• Pin Nos. 21 and 22 of COMIA and 23 and 24 of COMIB are connected internally.

25
Output Part
100-mA output circuit by power MOSFET
Item Specification
Number of output points 10 points
Rated load voltage 24 VDC; 60 VDC (peak) (without flywheel diode)
Maximum load current 100 mA per point
Residual voltage 1.8 V / 100 mA
Insulation method Photocoupler
Overcurrent protection Fuse resistance: 10 Ω, 0.1 W

Internal circuit configuration (Standard NPN specification)

Each output
Load
Fuse resistance:

Load
Internal circuit

Pin No.

External
power supply
Rectifier
24 VDC

• Supply 24 VDC between COMOA and COMOB. COMOA and COMOB have no polarities.
• Pin Nos. 1 & 2, and 3 & 4, are connected internally.
Note 1) The output circuit is an open-drain circuit provided by a power MOSFET and has no flywheel
diode. When connecting a load, such as a relay, also connect a diode, etc., to suppress flyback
voltage. (Spike noise can be eliminated most effectively when a diode is connected at the
closet possible position to the coil).

Internal circuit configuration (Optional PNP specification)

Pin No.

External
Rectifier power supply
24 VDC

Load
Internal circuit

Fuse resistance:
Each output
Load

26
3. 100/200-V Specification
3-1 Connection Method
3-1-1 Standard Type

ROBO Cylinder <RCS>

The cables are optional.

Host system <PLC>

Supplied flat
cable
EMG switch

Cable length:
2m
External unit
<RCA-105-5>
Optional
Cable length: 5 m

AC
power
supply

Class D grounding
(protective grounding)

External unit
<RCA-105-5>
Optional
Cable length: 5 m
PC

PC software Teaching pendant

<RCA-101-MW> <RCA-T/TD>
Optional Optional
Cable length: 5 m

27
3-2-2 Absolute Specification

ROBO Cylinder <RCS>

The absolute specification
cannot be used with a
standard actuator.
The cables are optional.

Other connections are the

same as those of the
standard type.

28
3-2 External Dimensions
3-2-1 Standard Type

29
3-2-2 Absolute Specification

30
3-3 100/200-V Controller

Item Specification
100 / 200 VAC
Supply voltage 90 ∼ 125 / 180 ∼ 250 VAC
RA55 (60 W), RA55 (100 W),
RB75 RB75 RB75 SMR
Type SSR (60 W), SMR (100 W),
(60 W) (100 W) (150 W) (150 W)
Supply current [VA] F55 (60 W) F55 (100 W)
Rating Peak 152 487 246 700 333 1026 166 546 265 902 364 1285

Maximum motor output 150 W (x 3)

Operating
0 to 40°C, 85%RH or less
temperature/humidity
Operating environment IP10, free from corrosive gases
Weight 1320 g
Regenerative voltage error, motor overcurrent, power-stage overheat,
Protective functions
encoder error, motor overload, overspeed
Withstand voltage (Note 2) 1500 VAC for 1 minute
LED indicators RDY (ready), RUN, ALM (alarm), ENC (encoder error)
DI/DO interface 24 VDC, insulated
Start
Command position number (4-bit binary)
8 dedicated
Pause
input ports
Reset
Servo ON
Completed position number (4-bit binary)
Input/output Position complete
(Note 1) Home return completion
Zone
11 dedicated Alarm
output ports Emergency stop
Moving
Battery alarm
Serial interface input/output
Number of positions 16
Data entry method Teaching pendant, PC software
Storage device EEPROM 8 kbytes, S-RAM 128 kbytes

(Note 1): Supplying the power-supply port or any I/O port with a voltage beyond the specified level may
result in controller failure.
(Note 2): The withstand voltage of the motor driving the actuator is 1000 V for 1 minute. When
conducting a withstand voltage test while the controller and actuator are connected, make sure
a voltage exceeding 1000 V is not supplied for more than 1 minute.

31
3-4 Names and Functions of Parts
3-4-1 Names

[1] Battery connector

(absolute specification)
[7] LED indicators
[2] Port switch
(PORT)
[8] Encoder/brake connector
[3] Brake release switch (ENC)
(BK)
[9] Piano switches 3
[4] Emergency-stop terminal block (SW3)
(EMG)
[10] Piano switches 2
(SW2)

[5] Motor connector [11] Piano switches 1

(SW1)

[12] PIO connector

[13] Main communication port

connector
(PORT IN)
[6] Power terminal block
[14] SIO connector
(SIO)

3-4-2 Functions

[1] Battery connector

A connector for absolute-data backup battery (absolute specification).

[2] Port switch (PORT)

ON: The PORT IN port (teaching pendant/PC software) becomes active. If a dedicated teaching
pendant or cable is not connected to this port, the controller will recognize an emergency-stop
condition.
OFF: The PORT IN port (teaching pendant/PC software) becomes inactive. (The SIO line remains
live, so controller-to-controller communication is possible.)

[3] Brake release switch (BK)

This switch is available only when the brake option is selected.
RLS: Brake is forcibly released
NOM: Brake is in use (Normal setting)

[4] Emergency-stop terminal block

EMG: Both terminals are used to connect an emergency-stop switch.

32
[5] Motor connector
A connector for the actuator’s motor power cable.

[6] Power terminal block

L/N: An AC-power connection terminal.
PE: A protective grounding terminal. Provide class D grounding.

[7] LEDs
RDY: Indicate that the CPU is operating normally.
RUN: This LED turns on while the actuator is moving.
ENC: This LED turns on when the encoder cable is open or otherwise the encoder cannot be
recognized.
The LED also turns on when the voltage of the absolute-data backup battery drops.
ALM: This LED remains lit while an alarm is present.

[8] Encoder/brake connector (ENC)

A connector for encoder/brake power cable.

[9] Piano switches 3

Switches for selecting the encoder voltage. Use these switches if a custom cable is used and
possibility of voltage drop must be taken into consideration.
Set switches 1 and 2 to ON or OFF in accordance with the cable length.

1 2 Cable length
ON OFF 1∼5m
OFF ON 5 ∼ 10 m
ON ON 10 ∼ 15 m

Note: All piano switches are designated as Nos. 1, 2, etc., from the bottom.

[10] Piano switches 2

1 (bottom): ABS-CLR. Clear the absolute encoder data. Set this switch to ON when performing an
absolute reset. --- Normally OFF
2 (top): FWP. Write protect switch. Set this switch to ON when performing a remote upload.
--- Normally OFF

33
[11] Piano switches 1 (SW1)
Nos. 1 to 4 --- Address switches

Use these switches to set the address of the applicable actuator if two or more axes are connected to
the SIO connector. A desired address between 0 to 15 can be set.
(The factory setting is OFF for all of switch Nos. 1 to 4. This setting represents a condition where only
one axis is used.)
Use these switches to set a desired address for each controller. Make sure no address is duplicated
among the controllers. As long as they are unique, the addresses may not be contiguous and missing
numbers are allowed.

Piano switch numbers

Address
1 2 3 4
0 OFF OFF OFF OFF
1 ON OFF OFF OFF
2 OFF ON OFF OFF
3 ON ON OFF OFF
4 OFF OFF ON OFF
5 ON OFF ON OFF
6 OFF ON ON OFF
7 ON ON ON OFF
8 OFF OFF OFF ON
9 ON OFF OFF ON
10 OFF ON OFF ON
11 ON ON OFF ON
12 OFF OFF ON ON
13 ON OFF ON ON
14 OFF ON ON ON
15 ON ON ON ON

The controller link cable is 200 mm

long.
A maximum of 16 controllers can be
connected.

Note: If multiple controllers are connected using link cables, the EMERGENCY STOP/ENABLE SW
on the teaching pendant (optional) becomes effective only with respect to the controller to
which the teaching pendant is connected.

34
[12] PIO connector (PIO)
A connector for PIO cable.

[13] Main communication port connector (PORT IN)

A connector for receiving the communication cable from a dedicated teaching pendant or external
equipment. It also receives a controller link cable when two or more axes are connected.

[14] SIO connector (SIO)

A connector for linking another controller when two or more controllers are connected.

35
3-4-3 Pin Assignments of the Communication Ports
Pin assignments of the SIO connector
Pin No. Signal name Function
1 (+5V) (5-VDC power output) or (preliminary signal terminal)
2 SGA Positive logic side of the line transceiver I/O
3 GND Communication ground
4 SGB Negative logic side of the line transceiver I/O
5 GND Communication ground
6 (+5V) 5-VDC power output

Pin assignments of the main communication port

Pin No. Signal name Function
1 SGA Serial communication
2 SGB Serial communication
3 5V 5-V power output
4 EMGS Emergency-stop status
5 EMGA *1
6 24V 24-V power output
7 GND Ground
8 ENGB *1

*1 Used to actuate an emergency stop (contact b).

Short these pins to cancel an emergency stop.

3-4-4 Pin Assignments of Each Connector, and Terminal Block Specifications

Motor connector [Molex 5569-04A1]
Pin No. Signal name Connected wire
1 PE Motor FG
2 U Motor phase U
3 V Motor phase V
4 W Motor phase W

36
Encoder/brake connector [High-density D-sub, DE-15 type]
Pin No. Signal name Connected wire
1 EN A+ Encoder A+
2 EN A– Encoder A-
3 EN B+ Encoder B+
4 EN B– Encoder B-
5 EN Z+ Encoder Z+
6 EN Z– Encoder Z-
7 SD+ Encoder SD+
8 SD– Encoder SD-
9 BAT+ (Battery+)
10 GND (Battery-)
11 EN 5N Encoder 5V+
12 EN GND Encoder COM-
13 BK N Brake -
14 BK P Brake +
15 FG Shield

Power terminal block [Phoenix]

Pin No. Connected wire
1 PE (Ground)
2 L (AC)
3 N (AC)

Emergency-stop terminal block

Pin No. Connected wire
1 EMG 1 (24 V)
2 EMG 2

37
3-4-5 I/O Flat Cable
• Supplied with the Controller

I/O connector (40P)

Flat cable

I/O connector (40P)

No Signal name Color No Signal name Color No Signal name Color No Signal name Color
1 COM-OA Brown-1 11 NC Brown-2 21 COM-IA Brown-3 31 NC Brown-4
Position
2 COM-OA Red-1 12 Red-2 22 COM-IA Red-3 32 Start Red-4
complete
3 COM-OB Orange-1 13 NC Orange-2 23 COM-IB Orange-3 33 NC Orange-4
Completed Command
4 COM-OB Yellow-1 14 Yellow-2 24 COM-IB Yellow-3 34 Yellow-4
position 8 position 8
5 NC Green-1 15 *Battery alarm Green-2 25 NC Green-3 35 NC Green-4
Completed Command
6 *Alarm Blue-1 16 Blue-2 26 *Pause Blue-3 36 Blue-4
position 4 position 4
7 NC Purple-1 17 Moving Purple-2 27 NC Purple-3 37 NC Purple-4
Completed Command
8 Zone Gray-1 18 Gray-2 28 Servo ON Gray-3 38 Gray-4
position 2 position 2
9 NC White-1 19 *Emergency stop White-2 29 NC White-3 39 NC White-4
Home return Completed Command
10 Black-1 20 Black-2 30 Reset Black-3 40 Black-4
completion position 1 position 1

• Optional

Output connector
(Split position)
I/O connector (40P)
Flat cable [A]
(Omron)

Input connector

[B]
(Omron)
(Omron)

[A] Output connector (20P) [B] Input connector (20P)

No Signal name Color No Signal name Color No Signal name Color No Signal name Color
1 COM-OA Brown-1 11 NC Brown-2 1 COM-IA Brown-1 11 NC Brown-2
Position
2 COM-OA Red-1 12 Red-2 2 COM-IA Red-1 12 Start Red-2
complete
3 COM-OB Orange-1 13 NC Orange-2 3 COM-IB Orange-1 13 NC Orange-2
Completed Command
4 COM-OB Yellow-1 14 Yellow-2 4 COM-IB Yellow-1 14 Yellow-2
position 8 position 8
5 NC Green-1 15 *Battery alarm Green-2 5 NC Green-1 15 NC Green-2
Completed Command
6 *Alarm Blue-1 16 Blue-2 6 *Pause Blue-1 16 Blue-2
position 4 position 4
7 NC Purple-1 17 Moving Purple-2 7 NC Purple-1 17 NC Purple-2
Completed Command
8 Zone Gray-1 18 Gray-2 8 Servo ON Gray-1 18 Gray-2
position 2 position 2
9 NC White-1 19 *Emergency stop White-2 9 NC White-1 19 NC White-2
Home return Completed Command
10 Black-1 20 Black-2 10 Reset Black-1 20 Black-2
completion position 1 position 1
* The I/O connector (40P) is the same as the supplied connector described above.

38
3-4-6 Backup Battery (Absolute Specification)
(1) Battery specifications
Item Description
Model AB-1
Classification Lithium battery
Manufacturer Toshiba Battery (ER6VP)
Nominal voltage 3.6 V
Rated capacity 2000 mAh
Weight Approx. 8.5 g
Battery retention time Note 1) Approx. 20,000 hours (at ambient temperature of 20°C)
Note 1) The absolute-data backup battery consumers approx. 100 µA during backup. (When the main
controller power is on, the current consumption is approx. 4 µA.)
* Do not modify or extend the cable. It may result in controller failure.
* The battery is replaced together with the battery board. The battery cannot be replaced alone. Be sure to
use the battery module specified by IAI.

(2) Battery alarm and battery error

A battery alarm (alarm code: 07A) will occur when the battery voltage drops to approx. 3.1 V. This
alarm is output to PIO connector pin No. 15. The controller operation will not be disabled right away
after a battery alarm occurs. The alarm merely indicates that the battery should be replaced soon.
Once a battery alarm occurs, the controller will generate a battery error in approx. 220 hours
(around nine days).
A battery alarm can be temporarily reset by inputting a reset signal or pressing the BEGIN/END key
on the teaching pendant for at least 2.5 seconds.
Note) The battery-alarm function is supported by the 100/200-V controller of version M5 or later.

A battery error will occur when the battery voltage drops to approx. 2.5 V. Once the battery voltage
drops to this level, the controller will detect an error (alarm code: 0E5) the next time the power is
turned on. A battery error is detected only when the controller power is turned on.
The controller operation will be disabled once a battery error occurs. You must replace the battery,
and then execute an absolute reset.

39
If the battery was replaced while the controller power was off, the position information (absolute data) may
or may not be retained depending on how long the controller remained without battery.

Time without battery Retention of position information (absolute data)

Less than 5 minutes Position information (absolute data) is retained. Absolute reset is not necessary.
A battery alarm occurs. Position information is retained. Absolute reset is not
5 to 15 minutes
necessary.
A battery error occurs. Position information is not retained. Absolute reset is
More than 15 minutes
necessary.

Note) The position-information (absolute-data) retention function during battery replacement is

supported by the 100/200-V controller of version M5 or later.
If a battery error was already present before the replacement, an absolute reset will be required
even if the controller has been without battery for no more than 15 minutes.

40
 3-5 Wiring
3-5-1 Wiring for Power Supply/Emergency Stop

AC power
supply

Class D grounding
(protective grounding)
Power terminal block

Emergency-stop terminal block

* The two EMG terminals are contact-b inputs used for connecting an emergency-stop switch. The
controller is shipped with these terminals shorted, so that an emergency stop will not be actuated. 24
VDC is output to EMG of pin No. 1.
The current consumption of the emergency-stop circuit is approx. 15 mA (100/200-V controller).

Note: When performing power connection, make sure the following specifications for power cable,
etc., are satisfied.

Single wire --- φ 1.0 (AWG18)

Applicable cable
Stranded wire --- 0.75 mm2 (AWG18)
Single wire --- φ 0.4 (AWG26) to φ 1.2 (AWG16)
Allowable wire size Stranded wire --- 0.3 mm2 (AWG22) to 1.25 mm2 (AWG16)
Element wire diameter --- φ 0.18 or larger
Standard stripped-wire length 11 mm
Button operation tool Flathead screwdriver (shaft diameter φ 3, blade tip width 2.6)

Note: This controller has no power switch.

41
3-5-2 External Connection Diagram
Screw onto a metal frame directly.

Controller

Start
Command position 1

Encoder Encoder Command position 2 Host

Output system
Command position 4

Command position 8
Brake
Pause
Reset
Servo ON

Completed position 1

Completed position 2

Completed position 4

Completed position 8

Position complete
Motor Home return Input
completion

Zone
Alarm
Moving
Emergency stop

Battery alarm
Conversion adapter

Main
communication
port Teaching pendant
Power
supply PC

To the next controller

If the controller cannot be screwed onto the frame

directly, connect it to the frame over a minimum
2
distance using a cable of 0.75 mm or larger.

Metal frame

42
3-5-3 PIO Interface
A PIO interface list is given below.
The PIO cable is a flat cable with no connector attached on the end connected to the external equipment.

PIO connector (40 pins)

Pin Reference Pin Reference
Category Signal name Cable color Category Signal name Cable color
No. No. No. No.
1 [1] COMOA Brown-1 2 [1] COMOA Red-1
3 [2] COMOB Orange-1 4 [2] COMOB Yellow-1
5 Green-1 6 [3] *Alarm Blue-1
7 Purple-1 8 [4] Zone Gray-1
Home return
9 NC White-1 10 [5] Black-1
completion
11 Brown-2 12 [6] Position complete Red-2
Output Output
13 Orange-2 14 Completed position 8 Yellow-2
15 [8] * Battery alarm Green-2 16 Completed position 4 Blue-2
[7]
17 [9] Moving Purple-2 18 Completed position 2 Gray-2
19 [10] * Emergency stop White-2 20 Completed position 1 Black-2
21 [11] COMIA Brown-3 22 [11] COMIA Red-3
23 [12] COMIB Orange-3 24 [12] COMIB Yellow-3
25 Green-3 26 [13] *Pause Blue-3
27 Purple-3 28 [14] Servo ON Gray-3
29 White-3 30 [15] Reset Black-3
31 Brown-4 32 [16] Start Red-4
Input NC Input
33 Orange-4 34 Command position 8 Yellow-4
35 Green-4 36 Command position 4 Blue-4
[17]
37 Purple-4 38 Command position 2 Gray-4
39 White-4 40 Command position 1 Black-4

Note: The ports indicated by an asterisk (*) conform to the contact-b signal logic (always ON).
Never connect those ports that are not used.

43
[1] COMIA
Power supply for output ports
[2] COMIB
Connect the 24-VDC power supply for output ports between COMOA and COMOB.
COMOA and COMOB have no polarities.
Pin Nos. 1 & 2, and 3 & 4, are connected internally.
[3] Alarm
This signal will turn OFF when an alarm occurs. It remains ON as long as the controller is operating
properly.
To reset an alarm, remove the cause of the alarm, and then input a reset signal or reconnect the
power.
[4] Zone
A zone signal will be output when the actuator enters the range set by the applicable parameter.
[5] Home return completion
This signal will turn ON when the initial home return is completed after a power connection.
Thereafter, this signal will remain ON until the power is turned off. It will not turn OFF following an
emergency-stop signal input.
If the home return completion signal is OFF, it means home return will be performed before the next
movement operation.

Note: With the absolute specification, the home return completion signal will turn ON when the power
is turned on, after an absolute reset was executed once. If the home return completion signal
turns OFF due to an alarm, an absolute reset must be executed again.

[6] Position complete

This signal will turn ON when the controller becomes ready following a power connection. It will turn
OFF when a start signal is input, and turn ON when a movement is completed.
[7] Completed position
All completed position signals will turn OFF the moment the position complete signal turns OFF.
All completed position signals remain OFF while an emergency stop is actuated or during the direct
teaching mode.
When the controller returns to the ready mode thereafter, the completed position signal
corresponding to the current actuator position will be output if the current actuator position is within
the positioning band from the last position complete position. If the current actuator position is outside
the positioning band, all completed position signals will remain OFF.
In the push & hold mode, all completed position signals will remain OFF when the controller returns
to the ready mode from an emergency-stop status or the direct teaching mode, regardless of the
current actuator position.
[8] Battery alarm (100/200-V specification)
With the absolute specification, this signal will turn OFF when the voltage of the backup battery drops
to 3.1 V or below (the alarm signal is a contact-b signal, meaning that it is always ON). This alarm
indicates that the battery should be replaced soon. The controller operation will not be disabled right
away after a battery alarm occurs. Once a battery alarm occurs, the controller will generate a battery
error in approx. 220 hours (around nine days).

Note) The battery-alarm function is supported by the 100/200-V controller of version M5 or later. With the
incremental specification, this signal remains OFF.

44
[9] Moving
This signal remains ON while the actuator is moving.
Use this signal if you want to detect stopping of the motor during pause.
[10] Emergency stop
This signal will turn OFF when an emergency stop is actuated. It remains ON as long as the
controller is operating properly.
When the emergency stop is cancelled, the signal will turn ON.
[11] COMIA
Power supply for input ports
[12] COMIB
Connect the 24-VDC power supply for input ports between COMIA and COMIB.
Pin Nos. 21 & 22, and 23 & 24, are connected internally.
[13] Pause
This is a contact-b input. Keep the signal ON while the actuator is moving, and cause it to turn OFF
when the movement pauses.
[14] Servo ON
The servo is ON while this signal is ON.
[15] Reset
An alarm will be reset once a rise of this signal is detected. If the cause of the alarm is not yet
removed, the alarm will come back after the reset action. (Only the overcurrent alarm (alarm code:
0C8) requires a power reconnection.)
When this signal is input while the actuator is in pause, the remaining travel will be cancelled.
[16] Start
Inputting this signal will start movement.
[17] Command position
Input the position number you want to select.
Relationship of input pin numbers and selected position numbers (4-bit binary)
One of 16 positions from 0 to 15 can be input/selected.

1: ON 0: OFF

40 Command position 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
38 Command position 2 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1
Pin No.
36 Command position 4 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
34 Command position 8 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
Selected position No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Note: The actuator will not operate if the start input is turned ON after selecting a position number for
which no position data is entered. (A bank 31 error (alarm code: 0B1) will occur.)

45
 3-5-4 100/200-V External I/O Specifications

Input Part
Item Specification
Number of input points 8 points
Input voltage 24 VDC ± 20 %
Input current 7 mA per circuit
ON voltage --- 16 V min. (4.5 mA)
Operating voltage
OFF voltage --- 6 V max. (1.4 mA)
Insulation method Photocoupler

Internal circuit configuration (Standard NPN specification)

Pin No.
External
power supply
24 VDC Rectifier

Internal circuit
Each input

• Connect a 24-V power supply between COMIA and COMIB.

• Connect the input common to the negative side of the external power supply.
• Pin Nos. 21 and 22 of COMIA and 23 and 24 of COMIB are connected internally.

Internal circuit configuration (Optional PNP specification)

Each input
Internal circuit

Pin No.

External
power supply Rectifier
24 VDC

• Connect a 24-V power supply between COMIA and COMIB.

• Connect the input common to the positive side of the external power supply.
• Pin Nos. 21 & 22 of COMIA and 23 & 24 of COMIB are connected internally.

46
Output Part
100-mA output circuit by power MOSFET
Item Specification
Number of output points 10 points
Rated load voltage 24 VDC; 60 VDC (peak) (without flywheel diode)
Maximum load current 100 mA per point
Residual voltage 1.8 V / 100 mA
Insulation method Photocoupler
Overcurrent protection Fuse resistance: 10 Ω 0.1 W

Internal circuit configuration (Standard NPN specification)

Each output
Load
Fuse resistance:

Load
Internal circuit

Pin No.

External
Rectifier power supply
24 VDC

• Supply 24 VDC between COMOA and COMOB.

• Pin Nos. 1 & 2, and 3 & 4, are connected internally.
Note 1) The output circuit is an open-drain circuit provided by a power MOSFET and has no flywheel
diode. When connecting a load, such as a relay, also connect a diode, etc., to suppress flyback
voltage. (Spike noise can be eliminated most effectively when a diode is connected at the
closet possible position to the coil).

Internal circuit configuration (Optional PNP specification)

Pin No.

External
Rectifier power supply
24 VDC
Internal circuit

Load
Fuse resistance:
Each output
Load

47
4. Data Entry <Basics>
This controller doesn’t use command words, so there is no need to create a program.

All you need is to enter position data in the position-data table, and the actuator will move to the specified
position.

Position data consists of number (No.), position (Position), speed (Speed), acceleration/deceleration
(ACC), push (Push), positioning band (Pos. band), and acceleration only MAX (ACC MAX). The
description in parentheses is as displayed on the teaching pendant.

Position data can be specified in two different modes: by absolute coordinate specification (absolute
mode) in which the distance from the home is entered, or by relative coordinate specification (incremental
mode) in which the incremental movement from the current position is entered.

Position-data table
Acceleration/ Positioning Acceleration
No. Position Note Speed Push
deceleration band only MAX
0 0 100 0.3 0 0.1 0
1 30 100 0.3 0 0.1 0
2 = 10 100 0.3 0 0.1 0
~ x x x x x x x ~
~ x x x x x x x ~
x x x x x x x
15 100 100 0.3 0 0.1 0

When data is entered in the position column of the position-data table, the default values will be
automatically entered in the remaining columns. Change the default values as necessary.
To change a default value, change the corresponding parameters starting with “Default.”
The default values vary depending on the actuator type.

This indicates that the incremental mode is active. (This symbol is displayed only on the teaching
pendant. Separate columns for incremental specification are provided in the PC software.)

Note: Enter position data first. Any attempt to enter other data before position data will be rejected.
You can enter position data containing two decimal places.
However, the controller only recognizes position data as a multiple of its minimum resolution.
The minimum resolution of the controller varies depending on the actuator lead.
For the above reason, the second decimal place in the entered position data may be rewritten
in accordance with the actuator lead.
Example: Entered value Stored value
→
50.01 50.03

48
4-1 Description of Position-Data Table
(1) No. • Indicate the position data number.
To enter an incremental movement, press the minus key in this column.
On the teaching pendant, a “=” will be displayed between the number
and position columns.
The minus key need not be pressed in the absolute mode.

(2) Position (Position) • Enter the target position to move the actuator to, in [mm].
Absolute mode: Enter the distance to the target actuator position from
the home. Negative values cannot be entered.
Incremental mode: Enter the distance to the target actuator position from
the current position. A negative value can also be
entered (for movement in the negative direction
along the displayed coordinate axis).

No. Position
0 30 Absolute mode 30 mm from the home
1 = 10 Incremental mode +10 mm from the current position
2 = -10 Incremental mode -10 mm from the current position
3 100 Absolute mode 100 mm from the home

(3) Speed (Speed) • Enter the speed at which the actuator will be moved, in [mm/sec].
The default value varies depending on the actuator type.

(4) Acceleration/deceleration • Enter the acceleration/deceleration at which the actuator will be moved,
(ACC) in [G].
The default value varies depending on the actuator type.

Speed

Speed
(Speed)

Acceleration/deceleration (ACC)

Start Completion Time

Acceleration/deceleration G --- MIN 0.01 G (Slow rise)

MAX 1.00 G (Quick rise)

(5) Push (Push) • Select the positioning mode or push & hold mode.
The default value is “0.”
0: Positioning mode (= Normal operation)
Other than 0: Push & hold mode [%]
• In the push & hold mode, enter the current-limiting value to be applied to
the servo motor while the load is being pushed. With the RCS, set the
current-limiting value to approx. 70%. The controller will not operate
properly if this value is 30% or below.

The table on page 52 lists the push force at standstill for each controller
type when the current-limiting value is set to 70%. Be sure to reference
this table to set an appropriate value for your controller.

49
 Note: If the push force is too small, a false detection of push & hold
condition may occur due to slide resistance, etc., so exercise
caution.

(6) Positioning band • The function of the positioning band varies depending on whether the
(Pos. band) push & hold setting in (5) is “0” or “other than 0.”
[A] Push = 0 (Positioning mode)
• In the positioning mode, enter the position-complete detection width
(distance to the target position), in [mm].
• The distance to the target position indicates the range prior to the target
position, upon entry of the actuator in which range a position complete
signal will be output.
The default value is “0.1 [mm]” (Fig. A).
[B] Push = Other than 0 (Push & hold mode)
• Enter the maximum push amount (distance from the target) in the push
& hold mode, in [mm] (Fig. B).
• If the push direction corresponds to the negative direction along the
displayed coordinate axis, add a – (minus) sign to the entered value.

(5) Push = 0 (5) Push = Other than 0

Speed
Speed

Distance to the position set in (2) Distance to the position set in (2)

Moving distance Moving distance

(6) Positioning band (6) Positioning band

Fig. A Fig. B

(7) Acceleration only MAX • Select the specified acceleration or maximum acceleration by entering
(ACC MAX) “0” or “1.”
The default value is “0.”
0: Specified acceleration --- The value entered in (4) becomes the
actual acceleration/deceleration.
1: Maximum acceleration --- The maximum acceleration set according
to the load is used.
The deceleration conforms to the value
entered in (4).

(7) Acceleration only MAX = 0 (7) Acceleration only MAX = 1

Acceleration/deceleration Acceleration/deceleration
Speed
Speed

Maximum acceleration
set in (4) set in (4)
according to the load

Moving distance Moving distance

50
4-1-1 Push Force at Standstill
In the push & hold mode, enter a current-limiting value (%) in the position-data table under “Push.”
With the RCS, use a push force at standstill corresponding to a current-limiting value of approx. 70%.
The push force at standstill can be increased or decreased by increasing or decreasing the current-limiting
value. However, take note that the controller will not operate properly if the current-limiting value is 30% or
below.
The table below lists the push force at standstill for each controller type when the current-limiting value is
set to 70%.

Push force
Type Motor (W) Speed type
(N (kgf))
L 95 (9.7)
RA35 20 M 47 (4.8)
H 23 (2.4)
L 142 (14.5)
RA45 30 M 70 (7.2)
H 35 (3.6)
L 178 (18.2)
60 M 89 (9.1)
H 44 (4.5)
RA55
L 296 (30.3)
100 M 149 (15.2)
H 74 (7.6)
L 142 (14.5)
Rod type 30 M 70 (7.2)
RB7525 H 35 (3.6)
M 143 (14.6)
60
H 71 (7.3)
L 238 (24.3)
60 M 118 (12.1)
RB7530 H 59 (6.1)
M 198 (20.2)
100
H 99 (10.1)
L 296 (30.3)
100 M 149 (15.2)
RB7535 H 74 (7.6)
M 222 (22.7)
150
H 111 (11.4)
L 142 (14.5)
F45 30 M 70 (7.2)
H 35 (3.6)
L 178 (18.2)
Flat type 60 M 89 (9.1)
H 44 (4.5)
F55
L 296 (30.3)
100 M 149 (15.2)
H 74 (7.6)

Note: The accuracy of push force at standstill is not guaranteed. The values are provided for
reference purposes only.

51
4-2 Explanation of Modes
4-2-1 Positioning Mode Push = 0

Position complete signal

Completed position number
Speed

(1) The position complete output will turn

Moving OFF
ON and moving output will turn OFF at
Output a position preceding the target position
by the positioning band. A completed
position number signal will be output at
the same time.
Moving distance
Positioning band

4-2-2 Push & Hold Mode Push = Other than 0

(1) Load was contacted successfully

(1) After reaching the target position, the

Position complete signal actuator will move at low speed.
Completed position number
Speed

When the Pos. band set in the data table

Moving OFF (see Note) is reached after the actuator
Output contacts the load and the servo motor
current has reached the current-limiting
value, the position complete output will
turn ON. A completed position number
Moving distance
signal will be output at the same time.
Positioning band The moving output will turn OFF.

Note: The time set in the parameter “Push & hold stop judgment period.” The default value of “255 msec”
is already entered.

The actuator is holding the load in position while pushing it.

The actuator continues to push the load at the push force at standstill determined by the
Warning current-limiting value. Since the actuator is not inactive, exercise due caution when
handling the machine in this condition.

The push speed is set as follows in accordance with the speed set in the position-data table:

Set speed
20 mm/sec or more Less than 20 mm/sec
Push speed 20 mm/sec Set speed

52
(2) Load was not contacted (missed)

(1) After reaching the target position, the

Completed position number actuator will move at low speed.
Speed

Moving OFF
Even after contacting the load, the actuator
Output
will move to the end of the positioning band
if the servo motor current is yet to reach the
current-limiting value.
The position complete output will not turn
ON even when the end of the positioning
Moving distance
Positioning band band is reached. In this case, only the
completed position number will be output.
The moving output will turn OFF.
Check if the load has stopped moving based
on whether the moving output has turned
OFF.
(3) Load moves during push & hold operation
[1] Load moves in the pushed direction
If the load moves in the pushed direction after
the position complete output has turned ON
Position complete signal (moving has turned OFF), the actuator will
Completed position number
Speed

push the load within the positioning band.

Output The moving output will turn ON.
Moving OFF The position complete output will remain ON
and the completed position number will be
output continuously.
Once the load stops moving, the moving
Moving distance output will turn OFF.
Positioning band

[2] Load moves in the opposite direction from the push force
(Actuator is pushed back by the reactive force of the load)

Position complete signal If the actuator is pushed back after the

Completed position number position complete output has turned ON
Speed

because the actuator thrust is smaller than

Output the reactive force of the load, the actuator
will be pushed back all the way until its thrust
balances out with the reactive force of the
load.
Moving distance The position complete output will remain ON
and the completed position number will be
output continuously.
The moving output will remain ON until the
load stops moving.

53
(4) Positioning band was entered with a wrong sign

Speed
If the positioning band is entered with a
wrong sign, the position will deviate by twice
the positioning band, as shown to the left, so
exercise due caution.

Moving distance
Positioning Positioning
band band

4-2-3 Speed Change during Movement

Speed control involving multiple speed levels is possible in a single operation. The actuator speed can be
decreased or increased at a certain point during movement.
However, the position at which to implement each speed change must be set.

Position 1 Position 2 Position 1 Position 2 Position 1 Position 2 Position 3

4-2-4 Operation at Different Acceleration and Deceleration Settings

The actuator will accelerate and decelerate at different speeds if “1” is entered under “Acceleration only
MAX” in the position data.
The acceleration will conform to the maximum acceleration set according to the load, while the
deceleration will conform to the value entered in “Acceleration/deceleration” of the position data.
Speed

Time

Maximum acceleration according to the load Deceleration can be set freely

54
4-2-5 Pause
This signal can be used to stop the actuator in case of emergency.
The movement of the actuator can be paused via an external input signal (pause).
For safety reasons, this signal is provided as a contact-b input (based on the negative logic).
The actuator will decelerate to a stop when the pause input is turned OFF, and resume movement when
the pause input is turned ON.

Pause signal

Actuator operation

The remaining movement of the actuator can be cancelled by turning ON the reset input during pause (the
movement will be cancelled upon rise of the reset input signal).

Pause signal

Reset

Actuator operation

4-2-6 Zone Signal Output

This signal is output while the actuator is moving inside a specified zone (the zone can be set in a desired
position).
By setting a zone signal in the applicable parameter beforehand, you can cause the zone signal to turn
ON when the actuator enters the specified zone (the zone can be set in any position, even at the center of
the stroke).

Zone signal ON

Zone signal setting range

55
4-2-7 Home Return
With the standard specification, home return must be performed after the power has been input or an
encoder open or CPU error alarm has been reset. Selecting a position number and then initiating a start
will cause the controller to automatically perform home return before commencing the subsequent
operation. Once home return is complete, the home return completion output will turn ON (standard
specification).
Home return alone cannot be performed using PIO. To move the actuator to the home position in a normal
condition, set a position number for which “0” is set in the position-data table under “Position,” and then
issue a movement command to that position.

With the absolute specification, home return is not necessary after the power has been input, as long as
an absolute reset was performed once.

4-3 Timing Chart

Start

Command position

Position complete

Completed position

Moving
*Pause

Acc/dec Description Minimum Maximum

T1 Start ON minimum duration 4 msec −
T2 Start OFF minimum duration 4 msec −
T3 Start ON → Command position hold time 6 msec −
T4 Start ON → Position complete OFF delay − 7 msec
T5 Position complete OFF → Moving ON delay − 1 msec
T6 Pause OFF → Moving OFF delay − *1
T7 Pause ON → Moving ON delay − 6 msec
T8 Position complete ON → Moving OFF delay − 2 msec
T9 Completed position OFF → Position complete OFF delay 0.1 msec 1 msec
T10 Position complete ON → Completed position output delay 0.1 msec 1 msec *2

*1: The maximum value will vary depending on the acceleration/deceleration.

*2: After the position complete signal turned ON, wait for at least the sequencer’s scan time before
checking the completed position.

56
5. Using the Controller <Practical Steps>
5-1 How to Start (Standard Type)
(Refer to 5-2, “How to Execute An Absolute Reset,” for the absolute specification.)

(1) Connect the motor/brake cables and encoder cable to the controller.
(2) Connect the host PLC to the PIO connector using the supplied flat cable.
(3) If two or more axes are connected, set the necessary items using the piano switches. For details,
refer to “Names and Functions of Parts.”
(4) Supply the main power to the controller’s terminal block.
(5) Turn ON the pause and servo ON inputs at the PIO connector.
(6) The controller is working properly if the RDY LED is lit. If the ALM LED is lit, there is an error. Refer to
the alarm table and take an appropriate action.

Note: PIO inputs/outputs must be issued after the position complete signal turns ON following the
power ON.

The controller is ready once the above operation is completed.

5-1-1 When the Controller Can/Cannot Operate

(1) The moment the power is turned on, the servo turns on. When the controller becomes ready, the PIO
position complete output will turn ON.
(2) The following chart shows the timing relationships of the PIO alarm/emergency-stop outputs and
controller’s operating status.

Alarm

Alarm occurs.

Emergency stop

Emergency-stop
switch is pressed.

Reset

Controller Controller Controller Controller Controller

can operate cannot operate can operate cannot operate can operate

57
5-2 How to Execute Absolute Reset (Absolute Specification)

Note) With the absolute specification, an encoder receive error (0E5) will occur when the power is
turned on for the first time after the battery or PG cable was disconnected. This does not indicate
fault. If this error occurs, execute an absolute reset by following the specified procedure.

The specific method to execute an absolute reset will vary depending on the controller version.
A label on which a serial number is printed is attached on the right side of the controller.
In the serial number, check the alphabet in the second digit from the last.
Example) SERIAL No. AD251031 J3
In this example, the controller version is “J.”
An absolute reset is executed in different ways on controllers of version J* or earlier (A* to J*) and
controllers of version K* or later (K*, L*, etc.) (* indicates a number).
(If the controller version is K* or later, perform home return from the teaching pendant or PC software
when executing an absolute reset.)

How to Execute an Absolute Reset on a Controller of Version K* or Later

[1] Connect the motor cable and encoder/brake cables to the controller.
[2] Connect the host PLC to the PIO connector using the supplied flat cable.
[3] If two or more axes are connected using a controller link cable, set the address using the piano
switches (SW) on the controller. For details, refer to 2-4, “Names and Functions of Parts,” in this
manual.
[4] Turn switch No. 1 (bottom switch) of the controller’s piano switches 2 (SW2) to ON (tilt to the right).
[5] Turn on the main controller power.
[6] Connect the battery to the controller.
[7] The ALM LED will illuminate.
[8] Turn ON the pause and servo ON input signals at the PIO connector.
[9] Input a reset signal via the PIO connector to reset the alarm.
[10] Perform home return from the teaching pendant or PC software.
[11] Turn switch No. 1 of the controller’s piano switches 2 (SW2) to OFF (tilt to the left).

An absolute reset has been executed.

58
 How to Execute an Absolute Reset on a Controller of Version J* or Earlier
[1] Connect the motor and encoder/brake cables to the controller.
[2] Connect the host PLC to the PIO connector using the supplied flat cable.
[3] If two or more axes are connected, set the address using SW1 on the controller. For details, refer to
“Names and Functions of Parts.”
[4] Move the actuator slider or rod to a position where it is in contact with the mechanical end on the
home side.
[5] Turn switch No. 1 (bottom switch) of the controller’s SW2 to ON (tilt to the right).
[6] Turn on the main controller power.
[7] Connect the battery to the controller.
[8] The RDY LED will illuminate.
[9] Turn switch No. 1 of the controller’s SW2 to OFF (tilt to the left). Note 1)
An absolute reset has been executed. The home has been set several millimeters ahead of the
current position (mechanical end) (the specific distance from the mechanical end will vary depending
on the actuator model).
[10] To operate the actuator right away, turn ON the PIO pause/servo ON inputs.

Note 1) If switch No. 1 of SW2 remains ON, the next time the power is turned on an absolute reset will
be executed based on the actuator position at that time.

Note 1) The absolute RCS controller can be used only with absolute RCS actuators. It cannot be used
with standard RCS actuators.

59
5-3 Movement after Power On (Standard Type)
Example of use in operation) After the power is turned on, move the actuator to the position 150 mm from
the home at a speed of 200 mm/sec.
Position-data table (Field(s) within thick line must be entered.)
Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 0 100 0.3 0 0.1 0
1 150 200 0.3 0 0.1 0
x
x
x

RCS controller
PIO Reference flow
Power ON
Signal name Category
[7] [4]
Start [1] Servo ON input ON

[3]
Command position 1 [2] Pause input ON
Command position 2
[3] Select/enter command position 1.
Command position 4 Input
Command position 8 [4] Start input ON
[2]
Pause
Home return starts.

P Reset
[1] Position complete output OFF
Servo ON [5]
L
[10]
Completed position 1
[6] Moving output ON
C
Completed position 2

Completed position 4 [7] Start input OFF

Completed position 8 Home return completes.

[9] [5]
Position complete
Output
[8] [8] Home return completion output ON
Home return completion

Zone Movement to position 1 starts.

Alarm
Position complete output turns ON 0.1 mm
Emergency stop [9] before position 1.
[11] [6]
Moving
[10] Completed position 1 is output.

With the absolute specification, the home

return completion signal will turn ON after [11] Moving output OFF
the power is turned on, and the actuator will
move directly to position 1 without
performing home return. Movement to position 1 completes.

60
 Power ON

Servo ON

Command position Position 1

Start Note

Pause

Position complete

Alarm

Emergency stop

Completed position
Position 1
* Home return
completion
Speed

Moving
Positioning band
*Actuator movement
Time

The position complete output will turn ON when the controller becomes ready following the power ON.
(The position complete output will not turn ON if the servo ON input is OFF.)
To check if the controller is ready, always check if the position complete output is ON.
All completed position outputs are OFF immediately after the power is turned on. When the commanded
movement is complete, the completed position will be output. If the movement command was to position
No. 0, all of the completed positions will remain OFF.
The actuator will not operate unless the pause input is turned ON.
T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)
* With the absolute specification, the home return completion signal will turn ON after the power is turned
on, and home return will not be performed.

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.
If the start input remains ON as shown below, the position complete output will not turn ON
even when the actuator movement is completed. The moving output will not turn OFF, either.
Start

Position complete

Moving 1 msec or less

Actuator

61
5-4 Positioning Mode (Back and Forth Movement between Two Points)
Example of use in operation) The actuator moves back and forth between two positions. The position 250
mm from the home is set as position 1, and the position 100 mm from the
home is set as position 2. The travel speed to position 1 is set as 200
mm/sec, and to position 2 is set as 100 mm/sec.

RCS controller
PIO Reference flow

Signal name Category

[1] Select/enter command position 1.
[13] [10] [5] [2]
Start [2] Start input ON
[1]
Command position 1
[9] Movement to position 1 starts.
Command position 2
Completed position OFF
Command position 4

Command position 8 Input [3] Position complete output OFF

Pause [4] Moving output ON

Reset [5] Start input OFF

P
Servo ON
[6] Position complete output ON
L [7] Completed position 1
[15] [7] Completed position 1 is output.
Completed position 2
C
[8] Moving output OFF
Completed position 4

Completed position 8 [9] Select/enter command position 2.

[14] [11] [6] [3]

Position complete Movement to position 1 completes.
Output
Home return completion [10] Start input ON

Zone Movement to position 2 starts.

Alarm
Completed position OFF
Emergency stop
[16] [12] [8] [4] [11] Position complete output OFF
Moving
[12] Moving output ON

[13] Start input OFF

[14] Position complete output ON

[15] Completed position 2 is output.

[16] Moving output OFF

Movement to position 2 completes.

62
 Position-data table (Field(s) within thick line must be entered.)
Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 * * * * * *
1 250 200 0.3 0 0.1 0
2 100 100 0.3 0 0.1 0
x
x
x

Command position Position 1 Position 2 Position 1

Start

Position complete

Moving Note Note Note

Completed position
Position 1 Position 2 Position 1
Speed

Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)
Each command position must be input after the position complete output has turned ON for the movement
to the previous position.

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.
If the start input remains ON as shown below, the position complete output will not turn ON
even when the actuator movement is completed. The moving output will not turn OFF, either.
Start

Position complete

Moving 1 msec or less

Actuator

63
5-5 Push & Hold Mode
Example of use in operation) The actuator is caused to move back and forth in the push & hold mode and
positioning mode. The position 280 mm from the home is set as position 1, and
the position 40 mm from the home is set as position 2.
Movement to position 1 is performed in the push & hold mode (the actuator is
caused to contact the load and push it in the counter-motor direction). The
maximum push amount at position 1 is set as 15 mm, and the current-limiting
value during the push & hold operation by the servo motor is set as 50%.
Movement to position 2 is performed in the positioning mode. The travel speed
to position 1 is set as 200 mm/sec, and that to position 2 is set as 100 mm/sec.
RCS controller
PIO Reference flow

Signal name Category [1] Select/enter command position 1.

[13] [10] [5] [2]
Start [2] Start input ON
[1]
Command position 1 Movement to position 1 starts.

[9] Completed position OFF

Command position 2

Command position 4 [3] Position complete output OFF

Input
Command position 8 [4] Moving output ON

Pause [5] Start input OFF

Reset Move at slow speed after passing position 1.

P
Servo ON Load is pushed. Servo motor current rises to
the current-limiting value.
L [7]
Completed position 1
[6] Position complete output ON
C [15]
Completed position 2
[7] Completed position 1 is output.
Completed position 4
[8] Moving output OFF
Completed position 8
[9] Select/enter command position 2.
[14] [11] [6] [3]
Position complete
Output [10] Start input ON
Home return completion
Movement to position 2 starts.
Zone
Completed position OFF
Alarm
[11] Position complete output OFF
Emergency stop
[12] Moving output ON
[16] [12] [8] [4]
Moving
[13] Start input OFF

[14] Position complete output turns ON 0.1

mm before position 2.

[15] Completed position 2 is output.

[16] Moving output OFF

Movement to position 2 completes.

64
 Position-data table (Field(s) within thick line must be entered.)
Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 * * * * * *
1 280 200 0.3 50 15 0
2 40 100 0.3 0 0.1 0
x
x
x

Command position Position 1 Position 2 Position 1

Start

Position complete

Moving Note Note Note

Completed position
Position 1 Position 2 Position 1
Speed
Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)
Each command position must be input after the position complete output has turned ON for the movement
to the previous position.

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.
If the actuator has missed the load, the position complete output will not turn ON as shown
below. The completed position will be output and the moving output will turn OFF.

Command position Position 1 Position 2 Position 1

Start

Position complete

Moving

Completed position
Position 1 Position 2 Position 1
Speed

Actuator movement

65
5-6 Speed Change during Movement
Example of use in operation) The actuator speed is reduced at a certain point during movement.
The position 150 mm from the home is set as position 1, and the position 200
mm from the home is set as position 2. The actuator is initially located between
the home and position 1. The actuator is moved to position 2 being the target
position, at a travel speed of 200 mm/sec to position 1 and that of 100 mm/sec
from position 1 to position 2.
Method) In this example, the actuator is caused to move to position 1 and to position 2
successively. Before the actuator is stopped at position 1, command position 2
must be selected/entered and the start signal must be input. To do this, set a
wide positioning band at position 1 and cause the start signal for movement to
position 2 to be input immediately after the completion signal for movement to
position 1 is output. (Command position 2 should be entered while the actuator
is moving to position 1.)
RCS controller
PIO Reference flow
[1] Select/enter command position 1.
Signal name Category
[11] [9] [5] [2] Start input ON
Start [2]

[1] Movement to position 1 starts at 200 mm/sec.

Command position 1
[6] Command position 2 Completed position OFF

Command position 4 [3] Position complete output OFF

Input
Command position 8 [4] Moving output ON

Pause [5] Start input OFF

P Reset Select/enter command position 2.

[6]

L Servo ON Position complete output turns ON

[7] 1 mm before position 1.
[8]
Completed position 1
C
[13] [8] Completed position 1 is output.
Completed position 2

Completed position 4 [9] Start input ON

Completed position 8 Movement to position 2 starts at 100 mm/sec.

[12] [10] [7] [3] Output
Position complete Completed position OFF

Home return completion [10] Position complete output OFF

Zone
[11] Start input OFF
Alarm
Position complete output turns ON
[12] 0.1 mm before position 2.
Emergency stop
*
[14] [4] Completed position 2 is output.
Moving [13]

[14] Moving output OFF

Movement to position 2 completes.

66
 Position-data table (Field(s) within thick line must be entered.)
Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 * * * * * *
1 150 200 0.3 0 1 0
2 200 100 0.3 0 0.1 0
x
x
x

Command position Position 1 Position 2

Start Note Note

Position complete

Completed position Position 2

Position 1

Moving

Speed

Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.

67
5-7 Operation at Different Acceleration and Deceleration Settings
Example of use in operation) Positioning is performed to the position 150 mm from the home (position 1)
at a speed of 200 mm/sec. The actuator will accelerate at the maximum
acceleration set according to the load, and decelerate at 0.1 G.
Method) Entering “1” under “Acceleration only MAX” in the position data will
automatically adjust the acceleration to the maximum acceleration set
according to the load.
Entering “0.1” under “Acceleration/deceleration” in the position data will set
the deceleration to 0.1 G.

RCS controller
PIO Reference flow

Signal name Category [1] Select/enter command position 1.

[5] [2]
Start
[1] [2] Start input ON
Command position 1

Command position 2
Movement to position 1 starts at the maximum
acceleration.
Command position 4
Input
Command position 8 Completed position OFF

Pause

P Reset [3] Position complete output OFF

L Servo ON
[7] [4] Moving output ON
Completed position 1
C
Completed position 2
[5] Start input OFF
Completed position 4

Completed position 8 Moves at constant speed (200 mm/sec).

[6] [3] Position complete Output

Home return completion Decelerates at 0.1 G.

Zone
Position complete output turns ON
Alarm [6]
0.1 mm before position 1.

Emergency stop
[8] [4] [7] Completed position 1 is output.
Moving

[8] Moving output OFF

Movement to position 1 completes.

68
 Position-data table (Field(s) within thick line must be entered.)
Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 * * * * * *
1 150 200 0.1 0 0.1 1
x
x
x

Command position Position 1

Start

Position complete

Completed position Position 1

Moving

Speed

Positioning band
Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.
If the start input remains ON as shown below, the position complete output will not turn ON
even when the actuator movement is completed. The moving output will not turn OFF, either.
Start

Position complete

Moving 1 msec or less

Actuator

69
5-8 Pause
Example of use in operation) The actuator is paused during movement.
Method) Use the pause input.

RCS controller
PIO Reference flow

Signal name Category [1] Select/enter a desired command position.

[5] [2]
Start
[2] Start input ON
Command position 1

Command position 2 Movement to the selected position starts.

[1]
Command position 4
Input
Completed position OFF
Command position 8
[8] [6]
Pause
[3] Position complete output OFF
P Reset

Servo ON [4] Moving output ON

L
Completed position 1
C [5] Start input OFF
[11] Completed position 2

Completed position 4
Pause input OFF (Actuator
[6] decelerates to a stop.)
Completed position 8
[10] [3] Output
Position complete
[7] Moving output OFF
Home return completion

[8] Pause input ON (Movement starts.)

Zone

Alarm
[9] Moving output ON
Emergency stop
[12] [9] [7] [4]
Moving [10] Position complete output ON

[11] Completed position is output.

[12] Moving output OFF

Movement to the selected position

completes.

70
 Command position

Start Note

Position complete

Completed position

Pause

Moving
4 msec or less
Speed

Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.

The remaining movement can be cancelled by turning ON the reset input during pause.
(The controller will detect a rise of the reset signal and cancel the remaining movement.)

Command position

Start

Position complete

Completed position

Pause
4 msec or more

Reset

Moving
Speed

Actuator movement

71
5-9 Zone Signal Output
Example of use in operation) While the actuator is moving a zone signal is output inside the zone
enclosed by distances of 40 mm and 120 mm from the home. (40 mm ≤
Zone signal output ≤ 120 mm)
Method) Use the parameters “Zone boundary+” and “Zone boundary–” to set the
zone in which the zone signal is output, as shown below:
Zone boundary+ 120
Zone boundary– 40

RCS controller
PIO Reference flow
Signal name Category Select/enter a desired command position.
[1]
[5] [2] Start
[2] Start input ON
Command position 1

[1] Command position 2 Movement to the selected position starts.

Command position 4
Input
Completed position OFF
Command position 8

Pause [3] Position complete output OFF

P Reset
[4] Moving output ON
L Servo ON

C Completed position 1 Start input OFF

[5]

[9] Completed position 2

[6] Actuator enters the zone. Zone output ON
Completed position 4

Completed position 8
[7]
Actuator exits the zone. Zone output
[8] [3] OFF
Position complete Output

Home return completion Position complete output ON

[8]
[7] [6]
Zone
[9] Completed position is output.
Alarm

Emergency stop Moving output OFF

[10]
[10] [4] Moving
Movement to the selected position
completes.

72
 Command position

Start Note

Position complete

Completed position

Zone

Moving

Speed

Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.

Example of other zone output)

Zone output at 120 or more Zone output at 40 or less

Zone Zone

Zone boundary+ Maximum stroke length Zone boundary+ 40

Zone boundary– 120 Zone boundary– 0

73
5-10 Returning Home
Example of use in operation) Home return alone cannot be performed using PIO.
Method) Create point data of 0 distance from the home, and move the actuator to
that position.
Enter home data in position 0. To return home, move the actuator to
position 0.

Position-data table (Field(s) within thick line must be entered.)

Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 0 100 0.3 0 0.1 0
1 * * * * * *
x
x
x

RCS controller
PIO Reference flow
Signal name Category Select/enter a desired command
[1]
position. (Command positions 1, 2, 4
[5] [2] and 8 are all OFF)
Start

Command position 1

Command position 2 [2] Start input ON

[1]

Command position 4 Input Movement to position 0 (home) starts.

Command position 8

Pause Completed position OFF

P
Reset
L Servo ON [3] Position complete output OFF

C Completed position 1
[4] Moving output ON
Completed position 2

Completed position 4 Start input OFF

[5]
Completed position 8
[6] [3]
Position complete Output Position complete output turns ON 0.1
[6]
mm before position 0.
Home return completion

Zone [7] Moving output OFF

Alarm

Emergency stop Movement to position 0 completes.

[7] [4]
Moving

74
 Command position Position 0 Turn all of command positions
1, 2, 4 and 8 OFF.

Start Note

Position complete

Completed position Completed positions 1,

2, 4 and 8 all turn OFF.

Moving

Speed

Actuator movement

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)

Data of 0 distance from the home need not be always entered in position 0.
In this example, data of 0 distance from the home was entered in position 0. Of course, such data can also
be entered in any other position of 1 to 15.

Note: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.
If the start input remains ON as shown below, the position complete output will not turn ON
even when the actuator movement is completed. The moving output will not turn OFF, either.
Start

Position complete

Moving 1 msec or less

Actuator

75
5-11 Incremental Moves
Example of use in operation) The actuator is caused to move from the home to the 30-mm position, from
which it will be moved repeatedly in increments of 10 mm. The travel speed
from the home to the 30-mm position is set as 100 mm/sec, and that for 10-mm
incremental moves is set as 20 mm/sec.
RCS controller
PIO Reference flow

Category [1] Select/enter command position 1.

Signal name
[13] [10] [5] [2]
Start [2] Start input ON
[1]
Command position 1 Movement to position 1 starts.
[9]
Command position 2 Completed position OFF
Command position 4 Input
[3] Position complete output OFF
Command position 8
[4] Moving output ON
Pause
P Reset [5] Start input OFF

L Servo ON [6] Position complete output ON

[7]
Completed position 1 [7] Completed position 1 is output.
C
[15]
Completed position 2
[8] Moving output OFF
Completed position 4
Movement to position 1 completes.
Completed position 8
[14] [11] [6] [3]
Position complete [9] Select/enter command position 2.
Output
Home return completion [10] Start input ON

Zone Movement to +10 mm from the current position starts.

Alarm
Completed position OFF
Emergency stop
[16] [12] [8] [4] [11] Position complete output OFF
Moving
[12] Moving output ON

[13] Start input OFF

[14] Position complete output ON

[15] Completed position 2 is output.

[16] Moving output OFF

Movement to the +10 mm position completes.

76
 Position-data table (Field(s) within thick line must be entered.)
Acceleration/ Acceleration
No. Position Speed Push Positioning band
deceleration only MAX
0 * * * * * *
1 30 100 0.3 0 0.1 0
2 = 10 20 0.3 0 0.1 0
x
x
x

Command position Position 1 Position 2

Start
Note 1
Position complete Note 2

Completed position
Position 1 Position 2 Position 2

Moving
Speed

Actuator movement
Time

Distance from home

T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON
(The scan time of the host controller must be considered.)

Note 1: When the start signal turns ON, the position complete output will turn OFF and the moving
output will turn ON.
The start signal must be turned OFF with the confirmation that the moving output has turned
ON while the start signal remains ON.
If the start input remains ON as shown below, the position complete output will not turn ON
even when the actuator movement is completed. The moving output will not turn OFF, either.
Start

Position complete

Moving 1 msec or less

Actuator

Note 2: When a soft limit is reached as a result of repeated incremental moves, the actuator will stop
at that position and the position complete signal will be output.

77
5-12 Notes on Incremental Mode
(1) Notes on positioning operation
Selecting/entering a position number using relative coordinates during positioning will cause the
actuator to move to the position corresponding to the initial position plus the increment. (If the
increment is a negative value, the actuator will move to the position corresponding to the initial
position minus the increment.)
Example) If the start signal for movement to position 2 is input while the actuator is moving to
position 1, the actuator will move to the position 40 mm from the home.

Command position Position 1 Position 2 No. Position Speed

0 * *
Start 1 30 100
2 = 10 100
x x x
x x x
x x x
Position complete x
x
x
x
x
x

Completed position Position 2

Moving
Speed

Actuator movement
Distance
Position from home: 40

If the start signal for movement to an incremental position number is input multiple times during
positioning, the actuator will move to the position corresponding to the initial position plus the
“increment x number of times the signal was input.”
Example) If the start signal for movement to position 2 is input twice while the actuator is moving to
position 1, the actuator will move to the position 50 mm from the home.

Command position Position 1 Position 2

Start

Position complete

Completed position Position 2

Moving

Speed
Actuator movement
Distance
Position from home: 50

(2) Note on push & hold operation

If the start signal is input with an incremental position number selected/entered while the actuator is
moving in the push & hold mode, the actuator will move to the position corresponding to the position
at the time of start input plus the increment. Therefore, the end position will become indeterminate.

78
 Example) If the start signal for movement to position 2 is input while the actuator is moving to
position 1 in the push & hold mode, the actuator will move to the position 10 mm from
where it was when the input signal was input.

Command position Position 1 Position 2 No. Position Speed

0 * *
Start 1 50 100
2 = 10 100
x x x
x x x
x x x
Position complete x
x
x
x
x
x

Completed position Position 2

Speed

Actuator movement
Distance
10 mm

(3) Cumulative errors due to repeated incremental moves

Position data is recognized only as a multiple of the minimum resolution. The minimum resolution is
determined by the lead and the number of encoder pulses. Therefore, a margin of error may occur
between the entered position value and the actual movement of the actuator. If an incremental move
is repeated, this error will accumulate.
The maximum error range for each actuator type is shown below:

Motor Speed Screw Maximum Motor Speed Screw Maximum

Type Type
(W) type lead (mm) error (µ) (W) type lead (mm) error (µ)
L 2.5 0.2 L 2.5 0.3
SA4 20 M 5 0.3 RA35 20 M 5 0.6
H 10 0.6 H 10 1.2
L 3 0.2 L 2.5 0.2
SA5 20 M 6 0.4 RA45 30 M 5 0.3
H 12 0.7 H 10 0.6
L 3 0.2 L 4 0.2
Slider
SA6 30 M 6 0.4 60 M 8 0.5
type
H 12 0.7 H 16 1.0
RA55
M 6 0.4 L 4 0.2
SSR 60
H 12 0.7 100 M 8 0.5
M 10 0.6 H 16 1.0
100
H 20 1.2 L 2.5 0.8
SMR Rod
M 10 0.6 30 M 5 1.6
150 type
H 20 1.2 RB7525 H 10 3.3
L 2.5 0.2 M 5 1.6
60
F45 30 M 5 0.3 H 10 3.3
H 10 0.6 L 3 1.0
L 4 0.2 60 M 6 2.0
Flat
60 M 8 0.5 RB7530 H 12 3.9
type
H 16 1.0 M 6 2.0
F55 100
L 4 0.2 H 12 3.9
100 M 8 0.5 L 4 1.3
H 16 1.0 100 M 8 2.6
RB7535 H 16 5.2
M 8 2.6
150
H 16 5.2

79
6. Parameter Table

1 Zone boundary+ (mm) Maximum limit of the zone output range

2 Zone boundary– (mm) Minimum limit of the zone output range
3 Soft limit+ (mm) Set the soft limit in the positive direction.
4 Soft limit– (mm) Set the soft limit in the negative direction.
Home return direction
5 Set the home return direction.
(0: Reverse, 1: Forward)
In the push & hold mode, the position complete output will
Push & hold stop judgment period
6 turn ON if the current remains equal to or above the
(msec)
current-limiting value for the time set here.
7 Servo gain number Set the servo gain number.
8 Default speed (mm/sec) Default speed in the position-data table
Default acceleration/deceleration in the position-data
9 Default acceleration/deceleration (G)
table
10 Default positioning band (mm) Default positioning band in the position-data table
11 Default acceleration only MAX Default acceleration only MAX in the position-data table
Current-limiting value at standstill Determine the holding force at standstill after positioning
12 *
during positioning (%) operation.
Set the current-limiting value to be applied when the
Current-limiting value during home
13 actuator contacts the mechanical end during home return *
return (%)
(factory setting: 100%).
Set whether to enable or disable the dynamic brake at
standstill.
14 Operation-at-standstill flag
0: Disable
1: Enable (factory setting: 1)
15 Pause input disable selection 0: Enable, 1: Disable
Select an appropriate speed from 9600, 19200, 28800,
16 SIO communication speed
38400, 57600 and 115200 [bps].
A delay until the RCS controller returns a response after
Minimum delay time for slave
17 receiving a command from the host PLC/PC. Note) Set to
transmitter activation
5 msec or longer.

Parameter Nos. 1 to 14 are editable using the teaching pendant or PC software.

Parameter Nos. 15 to 17 are editable using the PC software.

*: If you need to change the parameter values, please contact IAI.

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• To change a soft limit, set a value corresponding to 0.3 mm outside of the effective range.
Example) Set the effective range to between 0 mm and 80 mm
Soft limit+: 80.3
Soft limit–: -0.3

Soft limits set in the controller

Approx. Approx.
0.3 mm 0.3 mm
Effective range

Approx. 0.1 mm Approx. 0.1 mm

Allowable jogging/inching range after home return

• If the home return direction is changed, all position data that have been entered will be cleared. If
necessary, back up the data before changing the home return direction.
• The home return direction cannot be reversed on a rod-type actuator.
• On a reversing-type actuator, the specified home return direction will be reversed (0: Forward, 1:
Reverse).

Note: After changing any parameter, reconnect the controller power.

The parameter will be rewritten simply by turning the emergency-stop switch or PORT switch
OFF and then turning it ON again. However, the new value may not become effective
depending on the parameter.

7. Alarm Table
When an alarm occurs, the ALM LED on the controller will illuminate.
The content of each alarm can be identified from the combination of the PIO alarm output and completed
position output.
Alarm Table
{ = ON z = OFF
Completed position No.
Alarm Content of alarm Alarm code*
8 4 2 1
{ Normal
z z { z { CPU error 0FA
z z { { z Nonvolatile memory data setting error 0B0, 0B1
z z { { { Home return error 0BE
z { z z z Alarm pertaining to servo error 0C0
z { z z { Power conversion error 0B8 ∼ 0CA
z { z { { Excessive deviation 0D8, 0DC
z { { z z Overload 0ED
z { { z { Open encoder or low battery voltage 0E4 ∼ 0E7
z { { { { Corrupted nonvolatile memory data 0F8

[1] To reset an alarm, input a PIO reset signal.

[2] If the alarm cannot be reset by a reset signal, a faulty controller or open encoder cable is suspected.

* These alarm codes are displayed on the teaching pendant and PC software. PIO completed
position signals will not be output if an alarm of any other code occurs.

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If the teaching pendant or PC software is used, the detailed codes shown in the table below will be
displayed. (The error names in the table are those displayed on the teaching pendant.)

Note: If the host is connected to the SIO connector, be sure to reference the error code table in
“Communication Protocol Specification.”

Alarm Code and Action Table

Code Error name Action

040 Emergency stop (This is not an error.) An emergency stop was detected. (Whether an
emergency stop is still active cannot be confirmed.)
05A Reception overrun Communication error. Check for noise and conflict between the SIO
master and slave stations.
05B Reception framing error Communication error. Check for shorted cable, noise and conflict
between the SIO master and slave stations.
05C Reception timeout error Communication error. Check for shorted cable, noise and conflict
between the SIO master and slave stations.
05D Header error Communication error. Check for noise and conflict between the SIO
master and slave stations.
05E Delimiter error Communication error. Check for noise and conflict between the SIO
master and slave stations.
07F BCC error Communication error. Check for noise and conflict between the SIO
master and slave stations.
061 FNCCHR, W address The command was rejected due to invalid data. This error also occurs
error when an address is assigned to a standalone controller using SIO (or
the teaching pendant). (Address must be assigned using the
switches.)
062 Operand 1 error The command was rejected due to invalid data (or the operation is not
supported by the applicable controller type).
063 Operand 2 error The command was rejected due to invalid data (or the operation is not
supported by the applicable controller type). If a standalone controller
is used, the speed may have been initialized to a value exceeding
2000 rpm when SW7 and SW8 on the controller are set to ON and
OFF, respectively.
064 Operand 3 error The command was rejected due to invalid data (or the operation is not
supported by the applicable controller type).
067 BCC error The command was rejected due to invalid data. A character other than
0 to 9 and A to F is included in the BCC.
070 Movement command The command was rejected because the execution condition was not
during RUN-OFF satisfied. The command may have been issued via external PIO.
071 PTP before home return The command was rejected because the execution condition was not
completion satisfied. The command may have been issued via external PIO.
073 Error reset during servo The command was rejected because the execution condition was not
ON satisfied. The command may have been issued via external PIO.
074 Operation during The command was rejected because the execution condition was not
excitation search satisfied. The command may have been issued via external PIO.
075 Operation command The command was rejected because the execution condition was not
during home return satisfied. The command may have been issued via external PIO.
07A ABS battery voltage low The voltage of the absolute-data backup battery is low (battery alarm).
This alarm can be temporarily reset, but replacement of the battery at
the earliest convenience is recommended.

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0B0 Bank 30 error If the error persists after reconnecting the controller power, the common
(Parameter) parameters must be edited or the controller must be initialized.
0B1 Bank 31 error (Point) If the error persists after reconnecting the controller power, the common
parameters/point data must be edited or the controller must be
initialized.
0BE Home return timeout Check the physical connection between the motor and actuator. The
motor/actuator may not be operating.
0C0 Overspeed Decrease the load or lower the acceleration/deceleration.

0C8 Overcurrent The main motor circuit may have shorted or an excessive load may
have been received momentarily. This alarm cannot be reset unless the
power is reconnected.
0C9 Overvoltage The load is excessive. Also check if the operation is locked.

0CA Overheating The ambient temperature may be too high.

0CB Current sensor error The current sensor generated an offset error.

0D8 Deviation overflow Check if the operation is locked.

0DC Push-back error The load was pushed back to a position outside the push range due to
an external force, etc.
0E0 Overload The load is excessive. Also check if the operation is locked.

0E4 Encoder send error The encoder receive IC generated a send error. Noise or faulty receive
IC board is suspected.
0E5 Encoder receive error Absolute reset has not been executed yet.
Battery error. Absolute reset must be executed after the absolute-data
backup battery is replaced.
The PG cable may be open or is not connected properly.
The encoder receive IC generated a send error. Noise or faulty receive
IC board is suspected.
0E6 Encoder count error The encoder generated a count error. This error occurs when the speed
exceeded 5000 rpm.
0E7 Open phase A/B/Z Check the encoder cable.

0F8 Damaged nonvolatile The controller must be initialized.

memory
0FA CPU error The CPU is not operating properly. Noise may have entered the CPU
circuit.
0FB FPGA error A FPGA error was detected.

101 Overrun error (S) Check the baud rate. Also check for conflict between the SIO master
and slave stations. (In update mode)
102 Framing error (S) Check the baud rate. Also check for shorted cable and conflict between
the SIO master and slave stations. (In update mode)
104 SCI R-QUE OV (S) Excessive data is received from outside the controller. (In update mode)

105 SCI S-QUE OV (S) The SCI send queue overflowed. (In update mode)

106 Termi R-BF OV (S) Excessive data is received from outside the controller. (In update mode)

10A Motorola S sum error The update program file is invalid. (In update mode)

10B Motorola S record The update program file is invalid. (In update mode)
error
10C Motorola S address The update program file is invalid. (In update mode)
error

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10D Motorola S file name The update program file is invalid. (In update mode)
error
10E Timing limit (W) (S) Check the address dip-switches for the TP-CPU board’s flash ROM.
(In update mode)
10F Timing limit (E) (S) Check the address dip-switches for the TP-CPU board’s flash ROM.
(In update mode)
111 Timing limit (P) (S) Check the address dip-switches for the TP-CPU board’s flash ROM.
(In update mode)
112 Input data error The input value is invalid. Enter a data within the allowable range.

113 Input too small The input value is too small. Enter a data within the allowable range.

114 Input too large The input value is too large. Enter a data within the allowable range.

115 Home return incomplete The operation is not permitted until home return is completed. Perform
home return first.
116 Last position data When adding a position, clear or delete the last position data first.

117 No moving data Movement cannot be performed because no position data is available.
Specify valid position data.
118 Selected axis not The selected axis is not connected. (This is not an error.)
connected
119 Too many TP parameter The parameters in the teaching pendant were changed beyond the
changes allowable limit after the update.
11A Flash verify error: S Check the address dip-switches for the TP-CPU board’s flash ROM.

11B Flash ACK timeout: S Check the address dip-switches for the TP-CPU board’s flash ROM.

11C Flash verify error: M Check the address dip-switches for the TP-CPU board’s flash ROM.

11D Flash ACK timeout: M Check the address dip-switches for the TP-CPU board’s flash ROM.

11E Paired data mismatch Enter paired data by paying attention to the magnitude relationship of
error the two data.
11F Absolute value too small The absolute value of the input is too small. Enter a data within the
allowable range.
120 Initialization factor error The factor data entered when the controller was initialized is invalid.
Enter a data within the allowable range.
121 Push search end over The position at which the push & hold operation ended is outside the
stroke range. Correct the position or positioning band.
122 Multiple axes connected Always assign an address with only one axis connected.
during address
assignment
180 Address change OK (This is not an error.)

181 Controller initialization (This is not an error.)

OK
182 All clear upon home (This is not an error.)
change
201 Emergency stop (This is not an error.)

20A Servo OFF during The servo turned OFF during operation.
operation
20C Start ON during The start input turned ON during operation.
operation

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20D STP OFF during The STP turned OFF during operation.
operation
20E Soft limit over during A soft limit was exceeded during operation.
operation
301 Overrun error (M) Check for noise and conflict between the SIO master and slave
stations.
302 Framing error (M) Check for shorted cable, noise and conflict between the SIO master
and slave stations.
304 SCI R-QUE OV (M) Excessive data is received from outside the controller.

305 SCI S-QUE OV (M) The SCI send queue overflowed (in the master station mode).

306 Termi R-BF OV (M) Excessive data is received from outside the controller.

307 Memory command The controller rejected the command. The cause of this error is
rejected unknown. Record the entire error list before turning off the TP power.
308 Response timeout (M) Check the cable and controller power. Also check for conflict between
the SIO master and slave stations.
309 Termi write address Indeterminable Termi write address.
error
30A Packet R-QUE OV Excessive data is received from outside the controller.

30B Packet S-QUE OV The packet send queue overflowed.

30C No connected axis Check the cable and controller power. Also check for conflict between
the SIO master and slave stations.

85
 Appendix

* Appendix
Example of Basic RCS Positioning Sequence
Given below is an example of basic sequence for creating a positioning sequence using the RCS.
indicates PIO signals of the RCS controller.
(Completed-position decoding circuit)
Position complete

Waiting for the completed position to be read

(Must be longer
Completed position codes than the PLC’s
scan time.)

Completed position 1

Completed position 2

Completed position 3

Completed position 4

Completed position 5

Create for the number of positions.

(Positioning circuit for position 1: When position 1 is set as the home)
Home return G
request
Home-return start pulse

Home return request

Auxiliary home-return start pulse

Positioning
start request
to position 1
Positioning start pulse to position 1 (home)

Positioning
start request
to position 1
Auxiliary positioning start pulse to position 1 (home)
The positioning start request signal is converted to pulse in such
a way that one start signal is issued for one positioning operation.

Home return completion

Auxiliary positioning start for position 1 (home)

Current positioning
completed position

Start signal Moving signal

Start check for position 1 (home)

Auxiliary start
signal for next
positioning

Completion of positioning to position 1 (home)

Check if positioning to the specified position has completed.

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 Appendix

(Positioning circuit for position 2)

Positioning
start request
to position 2
Positioning start pulse to position 2
Positioning
start request
to position 2
Auxiliary positioning start pulse to position 2

Current positioning
completed position

Auxiliary positioning start for position 2

Start signal Moving signal

Start check for position 2

Auxiliary start
signal for next
positioning
Completion of positioning to position 2
If a measure is taken to identify the current position in
the sequence in case the sequence stops in the middle,
as implemented in this circuit, even when a problem
occurs the cause can be identified more easily.

Create for the number of positions.

(Command position number
output encoding circuit)

Auxiliary start
position for Set signal
positioning to for other
other position position
Position 1 set

Auxiliary start
position for Set signal
positioning to for other
other position position
Position 2 set

The command position is held until positioning to

other position is started, in order to prevent the
command position from changing during positioning.

Create for the number of positions.

87
 Appendix

Command position 1
Position 3
set signal

Position 5
set signal

Command position 2
Position 3
set signal

Position 6
set signal

Command position 4

Command position 8

(Start signal circuit)

Waiting for start

5 msec or more
(Must be longer
than the PLC’s
scan time.)
Start
command
for
positioning
to other
position

Start signal

88
Catalog No.: RCSC-MJ0102-18A-May3105-2

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The information contained in this document is subject to change without notice for the purpose of product improvement.
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