RCP2 Series

ROBO Cylinder Controller

Operation Manual Eighth Edition
 CAUTION
1. 24-V Power Supplies for Equipment Requiring a UL Certification
The controller with the maximum current of 2 A is UL-certified. However, a UL certification requires
that the 24-V power supplies used with the controller conform to Class 2.
If the user’s equipment must receive a UL certification, please use an input power supply and an I/O
power supply both conforming to Class 2.

2. Basic Parameter Settings

After applying power, at least the three parameters specified below must be set in accordance with
the specific application.
Inappropriate settings of these parameters will prevent the controller from operating properly, so
exercise due caution.
For details on how to set the parameters, refer to “Parameter Settings” in the operation manual for
the PC or teaching pendant.

[1] Selecting the PIO pattern

This controller provides six PIO (Parallel I/O) patterns to meet the needs of various applications.
To select a desired PIO pattern, set a corresponding value from 0 to 5 in parameter No. 25 (PIO
pattern selection).
The factory setting is “0.”

Parameter No.
Feature of PIO pattern
25 setting
0 Conventional
This pattern is compatible with the pin assignments of the RCP controller.
1 Standard
All functions of the RCP controller are available, plus the home-return command
input, servo ON input, reset input, moving output and ready output.
2 64-point positioning
Compared with the standard pattern offering only 16 positioning points, this pattern
provides up to 64 positioning points.
However, the servo ON input, ready output and zone output have been removed.
3 2 zone output signals
Compared with the standard pattern offering only one zone output signal, this pattern
provides two zone output signals.
However, the moving output has been removed.
The boundaries for the second zone output signal are specified in parameter Nos. 23
and 24.
4 Teaching
This pattern allows for normal positioning operation, as well as jogging and writing of
current position to a specified position using I/Os.
Switching between the normal positioning mode and teaching mode is effected by the
MODE input signal.
The mode switching completion output has been added to indicate that the modes
have been switched.
However, the zone output has been removed.
(Note) Position data can be rewritten up to around 100,000 times.
5 4 points (air cylinder)
Use of the RCP2 as an air cylinder is assumed in this pattern.
The number of positioning points is limited to four, but a direct command input and a
position complete output are provided for each target position in line with the
conventional practice of air cylinder control.
This lets the user control the RCP2 just like an air cylinder.
[2] Enabling/disabling the servo ON input signal (SON)
The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side.
Depending on the needs, therefore, the user must enable/disable this signal.
To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection).
Setting
Enable (use) the signal 0
Disable (do not use) the signal 1
If “0” or “2” has been selected as the above PIO pattern, the servo ON signal is not provided.
However, you must still set “1: [Disable]” in parameter No.21 (SON). (If “0” is set, the servo will not
turn ON.)
The factory setting for this parameter is “1: [Disable].”

[3] Enabling/disabling the pause signal (*STP)

The pause signal uses the contact B logic to provide a failsafe function.
Therefore, this signal must remain ON in normal conditions of use.
(The pause signal must also remain ON when issuing movement commands from the teaching
pendant or PC.)
Since there are applications where this signal is not used, a parameter is provided to disable the
pause signal so it doesn’t have to be turned ON.
To select a desired setting, set “0” or “1” in parameter No. 15 (Pause input disable selection).
Setting
Enable (use) the signal 0
Disable (do not use) the signal 1
If the pause input is not used, set “1: [Disable]” in this parameter and the signal need not be turned
ON.
The factory setting for this parameter is “0: [Enable].”

3. Recommendation for Backing up Latest Data

This controller uses nonvolatile memory to store the position table and parameters. Normally the
memory will retain the stored data even after the power is disconnected. However, the data may be
lost if the nonvolatile memory becomes faulty.
(We strongly recommend that the latest position table and parameter data be backed up so that the
data can be restored quickly in the event of power failure, or when the controller must be replaced for
a given reason.)
The data can be backed up using the following methods:
[1] Save to a CD or FD from the PC software.
[2] Hand write the position table and parameter table on paper.

4. Compatibility of Teaching Pendant

The existing teaching pendants of <RCA-T> and <RCA-E> types can be used with the RCP2
controller, but your RCA-T/RCA-E teaching pendant will require some modification.
If you are using a teaching pendant of either type, please send it to IAI. We will perform the
necessary modification and return it to you as soon as possible.
Teaching pendants that have already been modified have a specific code at the end of their serial
number. Please check the serial number of your teaching pendant to see if it requires modification.

Teaching pendant model Code at the end of serial number

RCA-T …F3 (or later)
RCA-E …H3 (or later)
RCA-P …H3 (or later)
RCB-J …B2 (or later)
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.
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.

[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, since the product uses DC voltage.)

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.

Others
Q IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the items
specified in “Safety Precautions.”
Q 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 Handling of Secondary Batteries for the Absolute Specification .................................................. 1
1.3 Safety Precautions ....................................................................................................................... 2
1.4 Warranty Period and Scope of Warranty ..................................................................................... 3

2. Specifications ...................................................................................... 4
2.1 Basic Specifications ..................................................................................................................... 4
2.1.1 Backup Batteries for the Absolute Specification .................................................................... 5
2.1.2 Specifications of the Large-Capacity Type............................................................................. 6
2.2 Name and Function of Each Part of the Controller ...................................................................... 7
2.2.1 Names.................................................................................................................................... 7
2.2.2 Functions................................................................................................................................ 7
2.3 External Dimensions .................................................................................................................... 9
2.3.1 Standard Specification ........................................................................................................... 9
2.3.2 Absolute Specification with Battery Bracket......................................................................... 10
Absolute Specification without Battery Bracket.....................................................................11
2.3.3 Large-Capacity Type ............................................................................................................ 12

3. Installation and Noise Elimination ..................................................... 13

3.1 Installation Environment............................................................................................................. 13
3.2 Power Supply ............................................................................................................................. 13
3.3 Noise Elimination and Grounding .............................................................................................. 13
3.4 Heat Radiation and Installation .................................................................................................. 15

4. Wiring ................................................................................................ 16
4.1 Internal Drive-Power Cutoff Relay Type..................................................................................... 16
4.1.1 Configuration........................................................................................................................ 16
4.1.2 External Connection Diagram .............................................................................................. 17
4.1.3 Wiring the Power Supply/Emergency-Stop Switch .............................................................. 18
4.2 External Drive-Power Cutoff Relay Type.................................................................................... 26
4.2.1 Configuration........................................................................................................................ 26
4.2.2 External Connection Diagram .............................................................................................. 27
4.2.3 Wiring the Power Supply/Motor Power Cutoff Relay ........................................................... 28
4.3 Connecting the I/O Cables ......................................................................................................... 31
z PIO pattern 0 [Conventional] ...................................................................................................... 31
z PIO pattern 1 [Standard]............................................................................................................. 32
z PIO pattern 2 [64-point positioning]............................................................................................ 33
z PIO pattern 3 [2 zone output signals] ......................................................................................... 34
z PIO pattern 4 [Teaching]............................................................................................................. 35
z PIO pattern 5 [4 points]............................................................................................................... 36
 4.4 Connecting the Actuator............................................................................................................. 37
4.4.1 Motor Relay Cable ............................................................................................................... 37
4.4.2 4.4.2 Encoder Relay Cable .................................................................................................. 38
z [Standard controller (2 A)]........................................................................................................... 38
z [Large-capacity controller (6 A)] ................................................................................................. 40
4.5 Connecting the Communication Cable ...................................................................................... 41

5. I/O Signal Control and Signal Functions ........................................... 42

5.1 PIO Patterns and Signal Assignments ....................................................................................... 42
5.1.1 Explanation of Signal Names............................................................................................... 43
z PIO pattern = “0: [Conventional],” “1: [Standard],”
“2: [64-point positioning],” “3: [2 zone output signals]”............................................................... 43
z PIO pattern = “4: [Teaching]” ...................................................................................................... 44
z PIO pattern = “5: [4 points] ......................................................................................................... 45
5.1.2 Signal Assignment Table for Respective PIO Patterns........................................................ 46
5.2 Interface Circuit .......................................................................................................................... 47
5.2.1 External Input Specifications................................................................................................ 47
5.2.2 External Output Specifications............................................................................................. 48
5.3 Details of I/O Signal Functions................................................................................................... 49
5.3.1. Details of Each Input Signal................................................................................................. 49
„ Start (CSTR) ............................................................................................................................... 49
„ Command position number ........................................................................................................ 49
„ Pause (*STP).............................................................................................................................. 49
„ Home return (HOME) ................................................................................................................. 50
„ Servo ON (SON)......................................................................................................................... 50
„ Alarm reset (RES) ...................................................................................................................... 50
„ Operation mode (MODE) ........................................................................................................... 50
„ Current-position write (PWRT) ................................................................................................... 51
„ Jog (JOG+, JOG-) ...................................................................................................................... 51
„ Movement to each position (ST0 to ST3)................................................................................... 51
5.3.2 Details of Each Output Signal .............................................................................................. 52
„ Completed position number (PM1 to PM32) .............................................................................. 52
„ Moving (MOVE) .......................................................................................................................... 52
„ Position complete (PEND).......................................................................................................... 52
„ Home return completion (HEND) ............................................................................................... 52
„ Zone (ZONE1, ZONE2) .............................................................................................................. 53
„ Current operation mode (MODES)............................................................................................. 53
„ Write completion (WEND) .......................................................................................................... 53
„ Completion of each position (PE0 to PE3) ................................................................................. 53
„ Ready (SRDY)............................................................................................................................ 54
„ Alarm (*ALM) .............................................................................................................................. 54
„ Emergency stop (*EMGS) .......................................................................................................... 54
Output Signal Changes in Each Mode ....................................................................................... 54
6. Data Entry <Basics>.......................................................................... 55
6.1 Description of Position-Data Table ............................................................................................. 56
6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value .................................. 58
(1) RPA type................................................................................................................................... 58
(2) RXA type................................................................................................................................... 58
(3) RSA type................................................................................................................................... 59
(4) RMA type .................................................................................................................................. 60
(5) RFA type ................................................................................................................................... 61
6.2 Explanation of Modes................................................................................................................. 62
6.2.1 Positioning Mode Push = 0 .................................................................................................. 62
6.2.2 Push & Hold Mode Push = Other than 0 ............................................................................. 62
6.2.3 Speed Change during Movement ........................................................................................ 64
6.2.4 Operation at Different Acceleration and Deceleration Settings ........................................... 64
6.2.5 Pause ................................................................................................................................... 65
6.2.6 Zone Signal Output .............................................................................................................. 66
6.2.7 Home Return........................................................................................................................ 66
6.2.8 Teaching Mode (Jogging/Teaching Using PIO) ................................................................... 67
6.2.9 Overview of the “4 Points” (Air Cylinder) Mode ................................................................... 68
6.3 Notes on the Robo Gripper (GRS/GRM) ................................................................................... 70

7. Operation <Practical Steps>.............................................................. 72

7.1 How to Start................................................................................................................................ 72
7.1.1 Standard Specification ......................................................................................................... 72
7.1.2 Absolute Specification (Absolute Reset).............................................................................. 74
7.2 How to Execute Home Return ................................................................................................... 77
7.2.1 Standard Specification ......................................................................................................... 77
7.2.2 Absolute Specification.......................................................................................................... 78
7.2.3 Operation Timings at PIO Pattern = “0: [Conventional]” ...................................................... 79
7.2.4 Operation Timings at PIO Pattern = “5: [4 Points]” .............................................................. 80
7.2.5 Operation Timings at PIO Pattern ≠ “0: [Conventional]” or “5: [4 Points]” ........................ 81
7.3 Home Return and Movement after Start (PIO Pattern = “1: [Standard]”) ................................ 82
7.4 Positioning Mode (Back and Forth Movement between Two Points) ........................................ 84
7.5 Push & Hold Mode ..................................................................................................................... 86
7.5.1 Return Action after Push & Hold by Relative Coordinate Specification ............................... 87
7.6 Speed Change during Movement .............................................................................................. 88
7.7 Operation at Different Acceleration and Deceleration Settings.................................................. 90
7.8 Pause ......................................................................................................................................... 92
7.9 Zone Signal Output .................................................................................................................... 94
7.10 Incremental Moves..................................................................................................................... 96
7.11 Notes on Incremental Mode ....................................................................................................... 98
7.12 Jogging/Teaching Using PIO.................................................................................................... 100
7.13 Operation in the “4 Points (Air Cylinder)” Mode ....................................................................... 102
8. Parameters...................................................................................... 106
8.1 Parameter Classification .......................................................................................................... 106
8.2 Parameter Table ....................................................................................................................... 106
8.3 Parameter Settings .................................................................................................................. 107
8.3.1 Parameters Relating to the Actuator Stroke Range........................................................... 107
z Soft limit .................................................................................................................................... 107
z Zone boundary ......................................................................................................................... 107
z Home return direction ............................................................................................................... 108
z Home return offset.................................................................................................................... 108
8.3.2 Parameters Relating to the Actuator Operating Characteristics ........................................ 108
z PIO jog speed........................................................................................................................... 108
z Default speed ........................................................................................................................... 108
z Default acceleration/deceleration ............................................................................................. 108
z Default positioning band (in-position) ....................................................................................... 109
z Default acceleration only MAX flag .......................................................................................... 109
z Push & hold stop judgment period ........................................................................................... 109
z Current-limiting value at standstill during positioning ................................................................110
z Current-limiting value during home return .................................................................................110
8.3.3 Parameters Relating to the External Interface....................................................................110
z PIO pattern selection .................................................................................................................110
z Movement command type .........................................................................................................111
z Pause input disable selection....................................................................................................112
z Servo ON input disable selection ..............................................................................................112
z Serial communication speed .....................................................................................................112
z Minimum delay time for slave transmitter activation .................................................................112
8.3.4 Servo Gain Adjustment .......................................................................................................112
z Servo gain number ....................................................................................................................112

9. Controlling Multiple Controllers via Serial Communication.............. 113

9.1 Basic Specifications ..................................................................................................................113
9.2 Connection Example .................................................................................................................113
9.3 SIO Converter ...........................................................................................................................114
9.4 Address Switch .........................................................................................................................116
9.5 Connection Cables....................................................................................................................116
9.6 Detail Connection Diagram .......................................................................................................117

10. Troubleshooting............................................................................... 118

10.1 Action to Be Taken upon Occurrence of Problem .....................................................................118
10.2 Alarm Level Classification .........................................................................................................119
10.3 Alarm Description Output Using PIO ....................................................................................... 120
10.4 Alarm Description and Cause/Action ....................................................................................... 121
(1) Message level alarms............................................................................................................. 121
 (2) Operation-cancellation level alarms ....................................................................................... 122
(3) Cold-start level alarms............................................................................................................ 125
10.5 Messages Displayed during Operation Using the Teaching Pendant or PC Software ............ 127
10.6 Specific Problems..................................................................................................................... 129
z I/O signals cannot be exchanged with the PLC. ...................................................................... 129
z The RDY lamp does not illuminate after the power is input. .................................................... 129
z Only the RDY lamp illuminates when the servo ON signal is input
after the power was input. ........................................................................................................ 129
z Both the RDY lamp and ALM lamp illuminate when the power is input. .................................. 129
z Home return ends in the middle in a vertical application.......................................................... 130
z Noise occurs during downward movements in a vertical application....................................... 130
z Vibration occurs when the actuator is stopped. ....................................................................... 130
z The actuator overshoots when decelerated to a stop. ............................................................. 130
z The home and target positions sometimes shift....................................................................... 130
z The speed is slow during push & hold operation. .................................................................... 130
z The actuator moves only a half of, or twice as much as, the specified movement.................. 131
z A servo error occurred while the actuator was moving (Robo Gripper). .................................. 131
z Abnormal operation results when the servo is turned ON after the power ON. ....................... 131

11. Function Check and Replacement of the Radiating Fan................. 132

* Appendix ................................................................................................ 134

Example of Basic RCP2 Positioning Sequence .................................................................................... 134
Recording of Position-Data Table .......................................................................................................... 137
Recording of Parameters ....................................................................................................................... 139
1. Note to the User
1.1 Introduction
Thank you for purchasing the RCP2 controller. This manual explains the features and operating
procedures of the product.

If not used or handled properly, even a brilliant 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.

1.2 Handling of Secondary Batteries for the Absolute Specification

Observe the safety precautions specified below when handling the secondary batteries:

1. Never attempt to disassemble the batteries. Strong alkali battery fluid will damage the skin or clothes.
2. Never short the battery terminals (i.e. by allowing the positive and negative terminals to make direct
contact). Doing so may damage the equipment or cause burns due to the generation of heat.
3. Never throw the batteries into a fire, because it may cause them to explode. Also avoid immersing the
batteries in water, which can result in loss of battery function.
4. Do not solder the batteries directly. The safety valve inside the battery cap may be damaged, resulting
in a breakdown of the safety mechanism.
5. If the battery connector remains connected for a long time without a supply of power, a deep discharge
may occur and cause the battery fluid to leak or allow the battery performance or life to
deteriorate/shorten significantly. If the equipment is to be relocated or modified and the power will not
be supplied for a prolonged period, first disconnect the battery connector.
6. When disposing of used batteries, drop them into the collection box at an authorized recycle store or
take other appropriate steps.

* 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
1.3 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 the specified genuine parts to wire your RCP2 controller and an actuator.

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
1.4 Warranty Period and Scope of Warranty
The RCP2 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
2. Specifications
2.1 Basic Specifications

Internal Drive-Power Cutoff Relay External Drive-Power Cutoff

Specification item
Type Relay Type
Model RCP2-C-*** (Note) RCP2-CG-*** (Note)
Number of controlled axes 1 axis/unit

Supply voltage 24 VDC ±10%

Supply current 2 A max.
Control method Weak field-magnet vector control (patent pending)
Position number specification
Positioning command
Direct specification
Position number Standard 16 points, maximum 64 points
Position number data and parameters are saved in nonvolatile
Backup memory memory.
Serial EEPROM can be rewritten 100,000 times.
10 dedicated inputs/10 dedicated outputs. Selectable from five
PIO
patterns.
LED indicators RDY (green), RUN (green), ALM (red)
Communication RS485 1 channel (terminated externally)
Encoder interface Incremental specification conforming to EIA RS-422A/423A
Forced release of electromagnetic
Toggle switch on front panel of enclosure
brake
Actuator cable: 20 m or less
Cable length
PIO cable: 5 m or less

Insulation strength 500 VDC, 10 MΩ

Environment Operating temperature 0 to 40°C
Operating humidity 85%RH or less (non-condensing)

Operating environment Not subject to corrosive gases.

Storage temperature -10 to 65°C
Storage humidity 90%RH or less (non-condensing)
10 to 57 Hz in XYZ directions / Pulsating amplitude: 0.035 mm
Vibration resistance
(continuous), 0.075 mm (intermittent)
Protection class IP20

Weight 300 g or less

External dimensions 35 W x 178.5 H x 68.1 D mm

(Note) *** indicates the actuator type.

4
2.1.1 Backup Batteries for the Absolute Specification
The absolute-specification controller uses secondary batteries (nickel metal hydride cells) to retain
absolute counter data in the FPGA (field-programmable gate array) after the power is cut off, and also to
supply power to the encoder’s drive circuit intermittently.

(1) Battery specification

Item Description
Classification Cylindrical sealed nickel metal hydride cell
Manufacturer Matsushita Battery Industrial
Model AB-4
Nominal voltage 4.8 V (1.2 V x 4)
Rated capacity 1900 mAh (average capacity: 2050 mAh)
Average life Approx. 4 years
Charging time Approx. 48 hours (at ambient temperature of 20°C)
Approx. 250 hours (when the batteries are fully charged, at
Retention time after power cutoff
ambient temperature of 20°C)

(2) Charging the batteries

Be sure to charge the batteries when the controller is powered up for the first time after delivery, and also
after new batteries have been installed.
The batteries are charged automatically while the power is being supplied to the controller, so keep the
main power on for at least 48 hours.
The actuator can be moved and the position table changed while the batteries are charging.
Additionally, charge the batteries for at least 48 hours after the power supply to the controller has been cut
off for a prolonged period (within the specified battery-retention time).

(3) Replacing the batteries

Batteries are consumable parts. Repeated charging and discharging of the batteries will diminish their
initial performance characteristics. If the retention time has decreased significantly, the batteries may have
reached the end of their useful life. If this should occur, replace the batteries.
The batteries should be replaced approximately four years after the controller is first connected to your
equipment, although the specific timing will vary depending on the ambient temperature and conditions of
charge/discharge.
The label on the battery unit shows a reference date, which is four years from the shipment date. Use this
date to determine when the batteries should be replaced.

Note: (1) Applying vibration, impact or other external force to the actuator or moving the slider, etc.,
while the power is off will erase the absolute data.
When the power is input again, the *ALM signal will turn OFF, the ALM lamp will illuminate
and the message “Absolute encoder error (2)” or “Absolute encoder error (3)” will be
displayed.
In this case, you must reset the alarm and perform a home return.
Never move the slider or rod while the power is off!
(2) It is recommended that the batteries be charged at normal temperature (+10 to +30°C) to
prevent extreme temperatures from negatively affecting the charging efficiency.
Temperatures exceeding 45°C may cause performance deterioration or the leakage of
battery fluid.

5
2.1.2 Specifications of the Large-Capacity Type

Specification item Internal Drive-Power Cutoff Relay Type

Model RCP2-CF-***
Number of controlled axes 1 axis/unit
Supply voltage 24 VDC ±10%
Supply current 6 A max.
Control method Weak field-magnet vector control (patent pending)
Position number specification
Positioning command
Direct specification
Position number Standard 16 points, maximum 64 points
Position number data and parameters are saved in nonvolatile
Backup memory memory.
Serial EEPROM can be rewritten 100,000 times.
10 dedicated inputs/10 dedicated outputs. Selectable from five
PIO
patterns.
LED indicators RDY (green), RUN (green), ALM (red)
Communication RS485 1 channel (terminated externally)
Encoder interface Incremental specification conforming to EIA RS-422A/423A
Forced release of electromagnetic
Toggle switch on front panel of enclosure
brake
Actuator cable: 20 m or less
Cable length
PIO cable: 5 m or less
Insulation strength 500 VDC, 10 MΩ
Environment Operating temperature 0 to 40°C
Operating humidity 85%RH or less (non-condensing)
Operating environment Not subject to corrosive gases.
Storage temperature -10 to 65°C
Storage humidity 90%RH or less (non-condensing)
10 to 57 Hz in XYZ directions / Pulsating amplitude: 0.035 mm
Vibration resistance
(continuous), 0.075 mm (intermittent)
Protection class IP20
Weight 300 g or less
External dimensions 35 W x 180 H x 71.6 D mm

6
2.2 Name and Function of Each Part of the Controller
2.2.1 Names

[1] Battery connector

(absolute specification)

[2] Status indicator LEDs

RDY (green) • RUN (green) • ALM (red)

[3] PIO pattern number label [7] I/O signal connector

[8] Address switch

[4] Teaching pendant/ [9] PORT switch

PC connector

[10] Encoder connector

[11] Brake release switch

[5] Motor connector

[6] Power/emergency-stop
terminal block

2.2.2 Functions
[1] Battery connector
A connector for the absolute data retention batteries.

[2] Status indicator LEDs

RDY: When lit, this LED indicates that 24V power is supplied and the CPU is operating.
RUN: This LED indicates the servo status. Lit = Servo is ON, Unlit = Servo is OFF.
ALM: When lit, this LED indicates that an alarm is present, or an emergency stop has been actuated
or the motor drive power is cut off.

[3] PIO pattern number label (IOPN)

Write down the PIO pattern selected in parameter No. 25 on this label.
(This will facilitate maintenance if multiple controllers are used in different patterns.)

[4] Teaching pendant/PC connector (SIO)

A connector for the dedicated teaching pendant or PC communication cable.
This cable is also used to link two or more controllers to enable serial communication among them.

7
[5] Motor connector (MOT)
A connector for the actuator’s motor power cable.

[6] Power/emergency-stop terminal block

[Built-in cutoff relay type RCP2-C, RCP2-CF]

Provide a contact output for the emergency-stop button on the teaching pendant.
Port switch ON = Emergency-stop button output (Contact B)
S1, S2
Port switch OFF = ON in normal conditions of use (Emergency-stop button output is
disabled)
Provide a contact for cutting off the motor drive power. MPI and MPO represent the
input side and output side of the motor power supply, respectively. (Short these
MPI, MPO
terminals using a jumper wire if not used. The controller is shipped with MPI and
MPO shorted.)
24V Positive side of the 24-V power supply
N Negative side of the 24-V power supply
EMG Emergency-stop input

[External cutoff relay type RCP2-CG]

Provide a contact output for the emergency-stop button on the teaching pendant.
Port switch ON = Emergency-stop button output (Contact B)
S1, S2
Port switch OFF = ON in normal conditions of use (Emergency-stop button output is
disabled)
Provide a contact for cutting off the motor drive power. MPI and MPO represent the
MPI, MPO input side and output side of the motor power supply, respectively. (Connect an
external safety circuit.)
24V Positive side of the 24-V power supply
N Negative side of the 24-V power supply
FG FG of the 24-V power supply

[7] I/O signal connector (PIO)

A PIO cable connector to the host controller (PLC, etc.).

[8] Address switch (ADRS)

A switch for setting the address for the controller axis.
If two or more controllers are connected in the serial communication mode, do not specify duplicate
controller addresses.
Setting range: 0 to F (A maximum of 16 controllers can be connected.)

[9] PORT switch (PORT)

A switch for enabling/disabling the serial communication port.
Set this switch to ON when connecting the controller to a teaching pendant or PC. Set it to OFF if no
teaching pendant or PC is connected.
* If this switch is turned ON without connecting a teaching pendant or PC, an emergency stop will be
actuated.

[10] Encoder connector (ENC)

A connector for the actuator’s encoder/brake cables.

[11] Brake release switch (BK)

A switch for forcibly releasing the brake when the actuator is used with a brake option.
RLS: Brake is forcibly released
NOM: Normal setting (Brake is controlled by the controller)

8
2.3 External Dimensions
2.3.1 Standard Specification (RCP2-***-I )
An external view and dimensions of the product are shown below.

(Mounting dimension)

9
2.3.2 Absolute Specification with Battery Bracket

(RCP2-***-A- -K)

(Mounting dimension)

*Weight: 660 g

10
Absolute Specification without Battery Bracket

(RCP2-***-A- )

(Mounting dimension)

*Weight: 460 g

11
2.3.3 Large-Capacity Type

(RCP2-CF-***)

(Mounting dimension)
Built-in
radiating fan

*Weight: 250 g

12
3. Installation and Noise Elimination

Pay due attention to the installation environment of the controller.

3.1 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.

3.2 Power Supply

The power supply specification is 24 VDC ± 10%.
(Supply current: 2 A max.)

3.3 Noise Elimination and Grounding

This section explains how to eliminate noise in the use of the controller.

(1) Wiring and power supply

[1] Provide a dedicated class D grounding using a wire with a size of 2.0 to 5.5 mm2 or larger.

Controller Other Other

equipment Controller equipment

Use a cable of a
maximum possible
size and keep the
wiring length at a
minimum.

Metal frame

Class D grounding Good Avoid this grounding method.

13
[2] 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.

(2) 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.

14
[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.

3.4 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 95 mm.

Fan
50 mm or more 95 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.

In the case of the dedicated controller for the high-thrust type, extra space is required to release the
exhaust heat from the radiating fan. Therefore, provide a clearance of 15 mm or more for this controller
type.

15
4. Wiring
4.1 Internal Drive-Power Cutoff Relay Type (RCP2-C, RCP2-CF)
4.1.1 Configuration

Standard teaching pendant

<RCA-T>
Optional
Cable length: 5 m
Host system <PLC>

Supplied flat
cable

Cable length: 2 m

External unit
<RCB-105-2> Cable length: 2 m ROBO cylinder
<RCB-105-5> Cable length: 5 m Cable length: 5 m
Optional Optional
PC
PERSONAL
COMPUTER

PC software External EMG switch

<RCB-101-MW> * Be sure that the
Optional communication port
S1
S2 switch is OFF when
MPI plugging in or
Input power supply MPO unplugging the
24 VDC 24V 24V communication port
0 N connector (SIO).
EMG

Note: Connect one end of the EMG switch to the 24-V output of the input power supply and the
other end to the S1 terminal. Also short the S2 and EMG terminals using a jumper wire.

16
4.1.2 External Connection Diagram
An example of standard wiring is shown below.
(Note) The encoder cable shown in the example is the standard cable for the controller with the
maximum current of 2 A.
As for the robot cable or the cable for the dedicated controller for the high-thrust type, refer to
4.4.2, “Encoder Relay Cable.”
Controller

(PORT switch)

Connected to teaching
pendant or PC

External EMG switch

Terminal block

Input power supply

24 VDC 24V
Actuator
0V
FG
Blue
Black
Host system
White
Red
Black
Motor
Green

flat cable
Yellow

Orange (black 2)

Orange (red 2)

Refer to 4.3, “Connecting the Yellow (black 1)

I/O Cables,” for the Yellow (red 1)

connection of I/O signals. White (black 1)

Encoder
White (red 1)

Light blue (black 1)

Light blue (red 1)

Holding
brake

Brake release switch

Tighten together with the

mounting screw.

17
4.1.3 Wiring the Power Supply/Emergency-Stop Switch
(1) Wiring the power supply
S1
S2
MPI
Input power supply MPO
24 VDC 24V 24V
0V N
(2 A max. per controller)
FG EMG

To connect multiple controllers, provide a relay terminal block.

Use a power cable satisfying the following specifications:

Item Specification
Applicable wire length Single wire: φ1.0 / Stranded: 0.8 mm2, AWG size 18, Copper wire
Stripped wire length 10 mm

* Use a flathead screwdriver with a blade tip of approx. 2.6 mm to push in the wire.

z Notes on wiring the absolute-specification controller

[1] When connecting a relay to the 24-V line, be sure to install it on the positive side of the 24-V power
supply.

Keep the negative side of the 24-V power supply connected without cutting it off with a relay.
If a relay is installed on both the positive and negative sides, an ABS error may generate.

[2] Connect a surge killer to the relay contact.

Chattering of the relay may have negative effect on the controller.

Connect a surge killer to prevent malfunction.

Surge killer Recommended product: Spark Killer by Okaya

Electric Industries
Model: CR-50500
Capacitance: 0.5 µF ± 20%
Resistance: 50 Ω (1/2W) ± 30%
24V+
24V- 24VPS AC
RCP-
ABS
Relay

Do not install a relay on the negative side.

18
(2) Wiring the emergency-stop switch
In many cases multiple controllers are used in a single system.
To provide an emergency-stop function for the entire system, the controller circuit is designed in such a
way that a single EMG switch is able to actuate an emergency stop in all connected controllers.
[Internal emergency-stop circuit] Teaching pendant

ON
EMG signal
OFF
S1
PORT
Relay
S2 switch
MPI
Input power supply MPO
(C: 2 Amax.) Motor
(C-RFA: 6 Amax.) 24V power
24V Controller supply
N power supply
0V
EMG

N
RCP2 controller
(Note) The current consumption of the internal relay is 10 mA or less.
(Reference) Cutoff voltage Cutoff current
EMG switch on teaching pendant 30 VDC 3A
PORT switch 24 VDC 0.1 A

[Example of recommended circuit] RCP2 controller

24V 0V
EMG switch on
teaching pendant
External EMG External EMG
reset switch circuit
S1 S2
CR

PORT switch Coil current:

CR
ON 0.1 A or less
OFF

MPI
MPO

24V N
CR
EMG
Relay

(Note) To cut off the motor drive power supply in conformance with safety category 2, connect 24V to the
EMG terminal and a contactor or other contact device to the MPI/MPO terminals. (Refer to 4.2.3.
(Refer to 4.2.3; rush current: 8 A.)

19
Representative connection examples are explained below.
z Connecting the teaching pendant directly to the controller (Parallel connection with the PLC)

[1] Connecting multiple controllers (8 units or less) using a single power supply
• Short the MPI and MPO terminals using a jumper wire. (The controller is shipped with these terminals
shorted.)
• Connect one end of the EMG signal to the 24-V output of the input power supply and the other end to
the S1 terminal.
Then, provide connections by sequentially connecting the S2 terminal of controller 1 to the S1 terminal of
controller 2, the S2 terminal of controller 2 to the S1 terminal of controller 3, and so on, and connect the
S2 terminal on the last controller to the EMG terminals on all controllers.
Use a relay terminal block for connection to the EMG terminals.
(Note) Do not connect two or more wires to one terminal.

20
 [Controller 1]
24V Teaching pendant 0V
EMG signal
S1 S2

ON
OFF
MPI
PORT switch
MPO
N
24V
Relay
EMG

[Controller 2]
Teaching pendant

S1 S2

ON
OFF
MPI
PORT switch
MPO
N
24V
Relay
EMG

[Controller 3]
Teaching pendant

S1 S2

ON
OFF
MPI
PORT switch
MPO
N
24V
Relay
EMG

[Controller 4]
Teaching pendant

S1 S2

ON
OFF
MPI
PORT switch
MPO
N
24V
Relay
EMG

21
[2] Using a power supply other than the input power supply
(Note) Since the controller’s PORT switch has a cutoff capacity of 0.1 A, use an auxiliary relay with a
coil current of 0.1 A or less and connect a diode for coil surge absorption.
control
C 0V [Controller 1] C 24V
Teaching pendant
EMG signal
S1 S2

power
P 24V P 0V ON
MPI OFF
MPO PORT switch
24V
N
Relay
CR
EMG

[Controller 2]
Teaching pendant

S1 S2

ON
MPI OFF
MPO PORT switch
24V
N
Relay
EMG

[Controller 3]
Teaching pendant
S1 S2
CR

ON

MPI OFF
PORT switch
MPO
24V
N
Relay
EMG

22
[3] Enabling the EMG switch on the teaching pendant for the connected axis or axes only

24V EMG signal 0V

CR
[Controller 1]
Teaching pendant
CR S2
S1

ON

MPI OFF
PORT switch
MPO
N
24V
Relay
EMG

[Controller 2]
Teaching pendant
S1 S2

ON

MPI OFF
PORT switch
MPO
N
24V
Relay
EMG

[Controller 3]
Teaching pendant
S1 S2

ON

MPI OFF
PORT switch
MPO
N
24V
Relay
EMG

23
z Connecting the teaching pendant to a SIO converter (Serial connection with the PLC)
Configure the contact circuit for the EMG switch on the teaching pendant using EMG1/EMG2 on the
power/emergency-stop terminal block on the SIO converter. (S1/S2 on the controller’s terminal block
are not used.)

24V 0V

SIO converter
Teaching pendant
EMG signal
EMG2 EMG1
CR

ON

OFF
PORT switch

[Controller 1]

MPI
MPO
N
24V
Relay
CR EMG

[Controller 2]

MPI
MPO
N
24V
Relay
EMG

[Controller 3]

MPI
MPO
N
24V
Relay
EMG

24
25
4.2 External Drive-Power Cutoff Relay Type (RCP2-CG)
4.2.1 Configuration

Standard teaching pendant

<RCA-T>
Optional
Cable length: 5 m
Host system <PLC>

Supplied flat
cable

Cable length: 2 m

External unit
<RCB-105-2> Cable length: 2 m Robo cylinder
<RCB-105-5> Cable length: 5 m Cable length: 5 m
Optional Optional

PC
PERSONAL
COMPUTER

PC software
<RCB-101-MW> Safety relay
Optional contactor for S1
motor drive- S2
power cutoff MPI
circuit MPO
Input power supply
24 VDC 24V 24V
0 N
FG FG

26
4.2.2 External Connection Diagram
An example of standard wiring is shown below.
(Note) The encoder cable shown in the example is the standard cable.
As for the robot cable, refer to 4.4.2, “Encoder Relay Cable.”

Controller

(PORT switch)

Connected to teaching
pendant or PC

Terminal block
Motor drive-
power cutoff
circuit

Input power supply Actuator

24 VDC 24V
0V
FG
Blue
Black
Host system
White
Red
Black
Motor
Green

flat cable
Yellow

Orange (black 2)

Orange (red 2)

Refer to 4.3, “Connecting Yellow (black 1)

the I/O Cables,” for the Yellow (red 1)

connection of I/O signals. White (black 1)

Encoder
White (red 1)

Light blue
(black 1)

Light blue
(red 1)

Holding
brake

Brake release switch

27
4.2.3 Wiring the Power Supply/Motor Power Cutoff Relay
(1) Wiring the power supply
S1
S2
MPI
MPO
Input power supply 24V
24 VDC 24V
0V N
(2 A max. per controller) FG
FG

To connect multiple controllers, provide a relay terminal block.

Use a power cable satisfying the following specifications:

Item Specification
Applicable wire length Single wire: φ1.0 / Stranded: 0.8 mm2, AWG size 18, Copper wire
Stripped wire length 10 mm

* Use a flathead screwdriver with a blade tip of approx. 2.6 mm to push in the wire.

z Notes on wiring the absolute-specification controller

[1] When connecting a relay to the 24-V line, be sure to install it on the positive side of the 24-V power
supply.

Keep the negative side of the 24-V power supply connected without cutting it off with a relay.
If a relay is installed on both the positive and negative sides, an ABS error may generate.

[2] Connect a surge killer to the relay contact.

Chattering of the relay may have negative effect on the controller.

Connect a surge killer to prevent malfunction.

Surge killer Recommended product: Spark Killer by Okaya

Electric Industries
Model: CR-50500
Capacitance: 0.5 µF ± 20%
Resistance: 50 Ω (1/2W) ± 30%
24V+
24V- 24VPS AC
RCP-
ABS
Relay

Do not install a relay on the negative side.

28
(2) Wiring the motor power cutoff relay
Explained below is a safety circuit conforming to safety category 2.
The user is responsible for implementing additional safety measures in the actual circuit configuration,
such as providing double contactor contacts to prevent fusing.

The circuit illustrated below is for reference purposes only.

• The input side of the motor drive power supply is connected to the MPI terminal, while the output side
is connected to the MPO terminal. Connect a contactor or other contact device to these terminals.
(Note) The rush current must be 8 A or less. The rated current is 2 A.
• The contact for the EMG switch on the teaching pendant is provided by the S1/S2 terminals.
(Note) When connecting the teaching pendant to a SIO converter, the contact for the EMG switch on the
teaching pendant is provided by the EMG1/EMG2 terminals on the SIO converter.

[Example of basic circuit]

Teaching pendant
EMG switch

(3A)

0V 24V

External EMG ON
External EMG
OFF
reset switch circuit
S1 PORT switch
(0.1 A)

MC

Coil current:
0.1 A or less S2
MC
MC
MPI
(Rush-in current: 8 A,
rated current: 2 A) MPO
Motor power
(MAX. 2A) 24V supply
Controller
N power supply

FG

RCP2 controller

29
[Connection example of a multiple-axis configuration]

Input power supply

24V Connect to 24-V terminal

0V Connect to N terminal
FG Connect to FG terminal
[Controller 1] [Controller 2] [Controller 3]
S1 S1 S1
S2 S2 S2
MPI MPI MPI
MPO MPO MPO
24V 24V 24V
N N N
FG FG FG

Contactor
EMG signal

External reset switch

S33 S34 S11 S12 13 23 33

Safety relay unit

Phoenix contact (PSR-SCP-24UC-/ESA2/4X1/1X2/B)

A1 A2 14 24 34

30
4.3 Connecting the I/O Cables
z PIO pattern 0 [Conventional]

Host system <PLC> end Controller end

Upper PIO (signal abbreviation)
stage Brown 1
+24 [V] 1A P24
Red 1
0 [V] 2A N
Orange 1
Start 3A CSTR
Yellow 1
Command position 1 4A PC1
Green 1
Command position 2 5A PC2
Blue 1
Command position 4 6A PC4
Output side

Purple 1
Command position 8 7A PC8
Gray 1
8A
White 1
9A
Black 1
Pause 10A *STP
Brown 2
11A
Red 2
12A
Orange 2
Lower 13A
stage Yellow 2
1B
Green 2
2B
Blue 2
Completed position 1 3B PM1
Purple 2
Completed position 2 4B PM2
Gray 2
Completed position 4 5B PM4
White 2
Completed position 8 6B PM8
Black 2
Input side

Position complete 7B PEND

Brown 3
Home return 8B HEND
completion Red 3
Zone output 9B ZONE
Orange 3
Alarm 10B *ALM
Yellow 3
Emergency stop 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”
Green 3
12B
Blue 3
13B

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional].

The pause signal may be disabled using parameter No. 15.

Blue 3

Lower stage 13A 13B

Upper stage 1A 1B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the
female pins in the connector. It may cause contact failure and disable normal operation of the
controller.

31
z PIO pattern 1 [Standard]
Host system <PLC> end Controller end
Upper PIO (signal abbreviation)
stage
Brown 1
+24 [V] 1A P24
Red 1
0 [V] 2A N
Orange 1
Command position 1 3A PC1
Yellow 1
Command position 2 4A PC2
Green 1
Command position 4 5A PC4
Blue 1
Command position 8 6A PC8
Output side

Purple 1
7A
Gray 1
Pause 8A *STP
White 1
Start 9A CSTR
Black 1
Home return 10A HOME
Brown 2
Servo ON 11A SON
Red 2
Reset 12A RES
Orange 2
Lower 13A
stage Yellow 2
1B
Green 2
2B
Blue 2
Completed position 1 3B PM1
Purple 2
Completed position 2 4B PM2
Gray 2
Completed position 4 5B PM4
White 2 6B PM8
Completed position 8
Black 2
Input side

Zone output 7B ZONE

Brown 3
Moving 8B MOVE
Position complete Red 3
9B PEND
Home return
Orange 3
10B HEND
completion
Yellow 3
Emergency stop 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”
Green 3
Ready 12B SRDY
Blue 3
Alarm 13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “1.”
To enable the servo ON signal, be sure to set parameter No. 21 to “0.” The pause signal may
be disabled using parameter No. 15.

Blue 3

Lower stage 13A 13B

Upper stage 1A 1B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the
female pins in the connector. It may cause contact failure and disable normal operation of the
controller.

32
z PIO pattern 2 [64-point positioning]
Host system <PLC> end Controller end
Upper PIO (signal abbreviation)
stage Brown 1
+24 [V] 1A P24
Red 1
0 [V] 2A N
Command position 1
Orange 1
3A PC1
Yellow 1
Command position 2 4A PC2
Green 1
Command position 4 5A PC4
Blue 1
Command position 8 6A PC8
Output side

Purple 1
Command position 16 7A PC16
Gray 1
Command position 32 8A PC32
White 1
Start 9A CSTR
Black 1
Home return 10A HOME
Brown 2
Pause 11A *STP
Red 2
Reset 12A RES
Orange 2
Lower 13A
stage Yellow 2
1B
Green 2
2B
Blue 2
Completed position 1 3B PM1
Purple 2
Completed position 2 4B PM2
Gray 2
Completed position 4 5B PM4
White 2
Completed position 8 6B PM8
Black 2
Input side

Completed position 16 7B PM16

Brown 3
Completed position 32 8B PM32
Red 3
Position complete 9B PEND
Home return Orange 3
completion 10B HEND
Yellow 3
Emergency stop 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”
Green 3
Moving 12B MOVE
Blue 3
Alarm 13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “2.”
The pause signal may be disabled using parameter No. 15.

Blue 3

Lower stage 13A 13B

Upper stage 1A 1B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the
female pins in the connector. It may cause contact failure and disable normal operation of the
controller.

33
z PIO pattern 3 [2 zone output signals]
Host system <PLC> end Controller end
Upper PIO (signal abbreviation)
stage Brown 1
+24 [V] 1A P24
Red 1
0 [V] 2A N
Orange 1
Command position 1 3A PC1
Yellow 1
Command position 2 4A PC2
Green 1
Command position 4 5A PC4
Blue 1
Command position 8 6A PC8
Output side

Purple 1
7A
Gray 1
Pause 8A *STP
White 1
Start 9A CSTR
Black 1
Home return 10A HOME
Brown 2
Servo ON 11A SON
Red 2
Reset 12A RES
Orange 2
Lower 13A
stage Yellow 2
1B
Green 2
2B
Blue 2
Completed position 1 3B PM1
Purple 2
Completed position 2 4B PM2
Gray 2
Completed position 4 5B PM4
White 2
Completed position 8 6B PM8
Black 2
Input side

Zone output 1 7B ZONE1

Brown 3
Zone output 2 8B ZONE2
Red 3
Position complete 9B PEND
Home return Orange 3
10B HEND
completion
Yellow 3
Emergency stop 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”
Green 3
Ready 12B SRDY
Blue 3
Alarm 13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “3.”
To enable the servo ON signal, be sure to set parameter No. 21 to “0.” The pause signal may
be disabled using parameter No. 15.

Blue 3

Lower stage 13A 13B

Upper stage 1A 1B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the
female pins in the connector. It may cause contact failure and disable normal operation of the
controller.

34
z PIO pattern 4 [Teaching]
Host system <PLC> end Controller end
Upper PIO (signal abbreviation)
stage Brown 1
+24 [V] 1A P24
Red 1
0 [V] 2A N
Orange 1
Command position 1 3A PC1
Yellow 1
Command position 2 4A PC2
Green 1
Command position 4 5A PC4
Blue 1
Command position 8 6A PC8
Output side

Purple 1
Operation mode 7A MODE
Gray 1
Pause/+Jog 8A *STP/JOG +
White 1
Start/Position write 9A CSTR/PWRT
Black 1
Home return 10A HOME
Brown 2
Servo ON 11A SON
Red 2
Reset/–Jog 12A RES/JOG -
Orange 2
Lower 13A
stage Yellow 2
1B
Green 2
2B
Blue 2
Completed position 1 3B PM1
Purple 2
Completed position 2 4B PM2
Gray 2
Completed position 4 5B PM4
White 2
Completed position 8 6B PM8
Black 2
Input side

Current operation 7B MODES

mode Brown 3
Moving 8B MOVE
Position complete/ Red 3
Write completion 9B PEND/WEND
Home return Orange 3
10B HEND
completion
Yellow 3
Emergency stop 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”
Green 3
Ready 12B SRDY
Blue 3
Alarm 13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “4.”
To enable the servo ON signal, be sure to set parameter No. 21 to “0.”
Be sure to enable the pause signal using parameter No. 15 (by setting the parameter to “0”)
(the pause signal is enabled at the factory). The system cannot switch to the teaching mode if
the pause signal is disabled (i.e., the above parameter is set to “1”).

Blue 3

Lower stage 13A 13B

Upper stage 1A 1B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the
female pins in the connector. It may cause contact failure and disable normal operation of the
controller.

35
z PIO pattern 5 [4 points] (air cylinder)
Host system <PLC> end Controller end
Upper PIO (signal abbreviation)
stage Brown 1
+24 [V] 1A P24
Red 1
0 [V] 2A N
Orange 1
Rear end move 3A ST0
Yellow 1
Front end move 4A ST1
Intermediate point Green 1
5A ST2
1 move
Intermediate point Blue 1
6A ST3
2 move
Output side

Purple 1
7A
Gray 1
Pause 8A *STP
White 1
9A
Black 1
10A
Brown 2
11A
Red 2
Reset 12A RES
Orange 2
Lower 13A
stage Yellow 2
1B
Green 2
2B
Blue 2
Rear end complete 3B PE0
Purple 2
Front end complete 4B PE1
Intermediate point Gray 2
5B PE2
1 complete
White 2
Intermediate point 6B PE3
2 complete Black 2
Input side

Zone output 7B ZONE

Brown 3
8B
Red 3
Position complete 9B PEND
Home return Orange 3
completion
10B HEND
Yellow 3
Emergency stop 11B *EMGS Available on “RCP2-C.” Not used on “RCP2-CG.”
Green 3
12B
Blue 3
Alarm 13B *ALM

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Note: The factory-set PIO pattern is [Conventional], so change the value in parameter No. 25 to “5.”
The pause signal may be disabled using parameter No. 15.

Blue 3

Lower stage 13A 13B

Upper stage 1A 1B

Brown 1

Note: When performing a continuity check of the flat cable, pay due attention not to expand the
female pins in the connector. It may cause contact failure and disable normal operation of the
controller.

36
4.4 Connecting the Actuator
4.4.1 Motor Relay Cable
• Connect the motor relay cable to the MOT connector.
Signal table for the controller-end connector (CN2)

Pin No. Signal Wire color Description

A1 A Blue Motor drive line (phase –A)
A2 VMM Black Motor power line
A3 B White Motor drive line (phase –B)
B1 A Red Motor drive line (phase +A)
B2 VMM Black Motor power line
B3 B Green Motor drive line (phase +B)

Controller end Actuator end

CN2 pin assignments CN1 pin assignments

1 2 3

4 6
A

CN1
CN2

1 3
B

CB-RCP2-MA * * *

CN2 CN1
Cable color Signal name Pin name Pin name Signal name Cable color
Blue A A1 1 A Red
Black VMM A2 2 VMM Black
White B A3 3 A Blue
Red A B1 4 B Green (yellow 3)

Black VMM B2 5 VMM Black

Green (yellow 3) B B3 6 B White

Housing: 1-1318119-3 (AMP) Housing: SLP-06V (J.S.T. Mfg.)

Receptacle contact: 1318107-1 Socket contact: BSF-21T-P1.4

37
4.4.2 4.4.2 Encoder Relay Cable
z [Standard controller (2 A)]
• Connect the encoder relay cable to the ENC connector.
Signal table for the controller-end connector (CN2)
Pin No. Signal Description
1 F.G Shielded wire
2 - (Not used)
3 - (Not used)
4 - (Not used)
5 GND Encoder power output
6 5V
7 VPS Encoder control signal output
8 - (Reserved)
9 EN B Encoder differential signal phase-B input
10 EN B
11 EN A Encoder differential signal phase-A input
12 EN A
13 BK – Negative side of the brake power supply
14 BK + Positive side of the brake power supply
15 - (Reserved)
16 - (Reserved)
z Cable colors and pin assignments for units shipped in and after August 2004 (supporting the absolute
specification)
Controller end Actuator end
CN2 pin assignments CN1 pin assignments

1 10
1 2
CN2

Standard cable CB-RCP2-PA * * * CN1 9 18

15 16
Robot cable CB-RCP2-PA * * *-RB
CN2
Cable color Signal Pin
Robot cable Standard cable name name CN1
- - (Reserved) 16 Pin Signal Cable color
- - (Reserved) 15 name name Standard cable Robot cable
Purple Red BK + 14 1 ENA Brown Blue
White (with purple) Gray BK – 13 2 ENA Green White (with blue)
Blue Brown ENA 12 3 ENB Purple Yellow
White (with blue) Green ENB 11 4 ENB Pink White (with yellow)
Yellow Purple 10 5 - - -
White (with yellow) Pink ENB 9 6 - - -
- - (Reserved) 8 7 - - -
Green Yellow VPS 7 8 - - -
Red Orange 5V 6 9 GND Blue White (with red)
White (with red) Blue GND 5 10 5V Orange Red
-- - - 4 11 VPS Yellow Green
- - 3 12 - - -
Drain
- - - 2 13 - - -
Drain F.G 1 14 - - -
Housing: PHDR-16VS (J.S.T. Mfg.) 15 - - -
Contact: SPHD-001T-P0.5 16 BK + Red Purple
17 BK – Gray White (with purple)
18 F.G Drain Drain

Housing: XMP-18V (J.S.T. Mfg.)

Contact: BXA-001T-P0.6
Retainer: XMS-09V

38
Reference: Cable colors and pin assignments for units shipped on or before July 31, 2004

Controller end Actuator end

CN2 pin assignments CN1 pin assignments

1 2
CN2 1 10

CN1
Standard cable CB-RCP2-PA * * *
15 16 9 18
Robot cable CB-RCP2-PA * * *-RB

CN2
Cable color Signal Pin
Robot cable Standard cable name name CN1
- - (Reserved) 16 Pin Signal Cable color
- - (Reserved) 15 name name Standard cable Robot cable
Light blue (red 1) Red BK + 14 1 ENA Brown White (red 1)
Light blue (black 1) Gray BK – 13 2 ENA Green White (black 1)
White (red 1) Brown ENA 12 3 ENB Purple Yellow (red 1)
White (black 1) Green ENA 11 4 ENB Pink Yellow (black 1)
Yellow (red 1) Purple ENB 10 5 - - -
Yellow (black 1) Pink ENB 9 6 - - -
- - (Reserved) 8 7 - - -
- - (Reserved) 7 8 - - -
Orange (red 2) Orange 5V 6 9 GND Blue Orange (black 2)
Orange (black 2) Blue GND 5 10 5V Orange Orange (red 2)
- - - 4 11 - - -
- - - 3 12 - - -
- - - 2 13 - - -
Drain Drain F.G 1 14 - - -
15 - - -
Housing: PHDR-16VS (J.S.T. Mfg.) 16 BK + Red Light blue (red 1)
Contact: SPHD-001T-P0.5 17 BK – Gray Light blue (black 1)
18 F.G Drain Drain

Housing: XMP-18V (J.S.T. Mfg.)

Contact: BXA-001T-P0.6
Retainer: XMS-09V

39
z [Large-capacity controller (6 A)]
• Connect the encoder relay cable to the ENC connector.
Signal table for the controller-end connector (CN2)
Pin No. Signal Description
1 F.G Shielded wire
2 - (Not used)
3 - (Not used)
4 5V Encoder power output
5 GND
6 - (Not used)
7 VPS Encoder control signal output
8 - (Reserved)
9 EN B Encoder differential signal phase-B input
10 EN B
11 EN A Encoder differential signal phase-A input
12 EN A
13 BK – Negative side of the brake power supply
14 BK + Positive side of the brake power supply
15 - (Reserved)
16 - (Reserved)

Controller end Actuator end

CN2 pin assignments CN1 pin assignments

Standard cable
Robot cable

Cable color Signal Pin

Robot cable Standard cable name name
(Reserved) Pin Signal Cable color
(Reserved) name name Standard cable Robot cable
Purple Red Brown Blue
White (with purple) Gray White (with blue)
Green
Blue Brown Purple Yellow
White (with blue) Green Pink White (with yellow)
Yellow Purple
White (with yellow) Pink
(Reserved)

Green Yellow
Blue White (with red)
White (with red) Blue
Red Orange Yellow Green
Orange Red

Drain Drain

Housing: PHDR-16VS (J.S.T. Mfg.) Red Purple

Contact: SPHD-001T-P0.5 Gray White (with purple)
Drain Drain

Housing: XMP-18V (J.S.T. Mfg.)

Contact: BXA-001T-P0.6
Retainer: XMS-09V

40
4.5 Connecting the Communication Cable
Connect the communication cable to the SIO connector.

Pin assignments of the cable-

end connector

RS485 conversion adapter end Controller end

6 8
CB-RCA-SIO * * *
3 5
1 2

Signal Pin Pin Signal

Cable color Cable color
name No. No. name
Brown 5V 1 1 SGA Yellow
Yellow SGA 2 2 SGB Orange
Red GND 3 3 5V Brown/Green
Orange SGB 4 4 EMGS -
Blue GND 5 5 EMGA Black
Green 5V 6 6 24V -
7 GND Red/Blue
Shorting wire UL1004AWG28 (black)
8 EMGB Black
Shielded, not connected FG Shielded

41
5. I/O Signal Control and Signal Functions
5.1 PIO Patterns and Signal Assignments
This controller provides six PIO (Parallel I/O) patterns to meet the needs of various applications.
To select a desired PIO pattern, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern
selection).
The features of each PIO pattern are explained below:
Parameter No.
Feature of PIO pattern
25 setting
0 Conventional
This pattern is compatible with the pin assignments of the RCP controller.
1 Standard
All functions of the RCP controller are available, plus the home-return command input, servo
ON input, reset input, moving output and ready output.
2 64-point positioning
Compared with the standard pattern offering only 16 positioning points, this pattern provides up
to 64 positioning points.
However, the servo ON input, ready output and zone output have been removed.
3 2 zone output signals
Compared with the standard pattern offering only one zone output signal, this pattern provides
two zone output signals.
However, the moving output has been removed.
The boundaries for the second zone output signal are specified in parameter Nos. 23 and 24.
4 Teaching
This pattern allows for normal positioning operation, as well as jogging and writing of current
position to a specified position using I/Os.
Switching between the normal positioning mode and teaching mode is effected by the MODE
input signal.
The mode switching completion output has been added to indicate that the modes have been
switched.
However, the zone output has been removed.
(Note) Position data can be rewritten up to around 100,000 times.
5 4 points (air cylinder)
Use of the RCP2 as an air cylinder is assumed in this pattern.
The number of positioning points is limited to four, but a direct command input and a position
complete output are provided for each target position in line with the conventional practice of
air cylinder control.
This lets the user control the RCP2 just like an air cylinder.

Quick reference table for functions available under each PIO pattern ({ --- Available, X --- Not available)
Number of Number of Input signals Output signals
No. 25 positioning zone output Home
points signals Servo ON Reset Jog Write Moving Ready
return
0 16 points 1 signal X X X X X X X
1 16 points 1 signal { { { X X { {
2 64 points None { X { X X { X
3 16 points 2 signals { { { X X X {
4 16 points None { { { { { { {
5 4 points 1 signal X X { X X X X
For details, refer to 5.1.2, “Signal Assignment Table for Respective PIO Patterns.”

Note: The servo ON input signal (SON) is not available if the conventional, 64-point or 4-point
positioning pattern is selected.
Therefore, always set parameter No. 21 (Servo ON disable selection) to “1: [Disable]” when
the controller is used in either of these PIO patterns.

42
5.1.1 Explanation of Signal Names
The following explains the signal names, and gives a function overview of each signal.
In the explanation of operation timings provided in a later section, each signal is referenced by its self-
explanatory name for clarity. If necessary, however, such as when marker tubes are inserted as a
termination of the flat cable, use the signal abbreviations.

z PIO pattern = “0: [Conventional],” “1: [Standard],” “2: [64-point positioning],” “3: [2 zone output
signals]”

Signal
Category Signal name Function overview
abbreviation
Input Start CSTR Movement is started at a rise edge of this signal.

Command position number PC1 The target position number is input.

PC2 A command position number must be specified by 6 ms before the
PC4 start signal (CSTR) turns ON.
PC8
PC16
PC32
*Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a stop

Home return HOME The actuator moves in the positive direction while this signal is ON.

Servo ON SON The servo remains ON while this signal is ON.

The servo remains OFF while this signal is OFF.

Alarm reset RES An alarm is reset at a rise edge of this signal.

Output Completed position number PM1 The relevant position number is output when positioning has
PM2 completed.
PM4 The signal will turn OFF when the next start signal is received.
PM8 It is used by the PLC to check if the commanded position has
PM16 definitively been reached, and also to provide a position interlock,
PM32 etc.
Moving MOVE This signal turns ON while the actuator is moving, and turns OFF
while it is stopped.
It is used for operation check and also to determine whether the load
is contacted during push & hold operation.
Position complete PEND This signal turns ON when the target position was reached and the
actuator has entered the specified in-position range.
It is used to determine whether positioning has completed.
Home return completion HEND This signal is OFF immediately after the power is input, and turns
ON when home return has completed.

Zone ZONE 1 This signal is output when home return has completed and the
ZONE 2 current actuator position is inside the range set by the applicable
parameter.
It can be used as a limit switch at an intermediate point or as a
simple ruler during push & hold operation.
Ready SRDY This signal is always output once the servo is turned ON and the
controller is ready to operate.
The signal is synchronized with the lit/unlit status of the “RUN” LED
on the front panel of the enclosure.
It is used by the PLC to determine when it can start operation.
*Alarm *ALM This signal remains ON in normal conditions of use and turns OFF
when an alarm generates.
It is synchronized with the unlit/lit status of the corresponding LED
on the front panel of the enclosure.
*Emergency stop *EMGS This signal is enabled on a “built-in cutoff relay” controller.
OFF: Emergency stop has been actuated

43
z PIO pattern = “4: [Teaching]”
Signal
Category Signal name Function overview
abbreviation
Input Start CSTR Movement is started at a rise edge of this signal.

Command position PC1 The target position number is input.

number PC2 A command position number must be specified by 6 ms before
PC4 the start signal (CSTR) turns ON.
PC8
*Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a
stop
Home return HOME Home return operation is started at a rise edge of this signal.

Operation mode MODE ON: Teaching mode, OFF: Normal mode

Current-position write PWRT When this signal has remained ON for 20 msec or longer, the
current position will be stored under the position number
selected by PC1 to PC8.
+Jog JOG+ The actuator moves in the positive direction while this signal is
ON.
–Jog JOG- The actuator moves in the negative direction while this signal is
ON.
Servo ON SON The servo remains ON while this signal is ON.
The servo remains OFF while this signal is OFF.
Alarm reset RES An alarm is reset at a rise edge of this signal.

Output Completed position PM1 The relevant position number is output when positioning has
number PM2 completed.
PM4 The signal will turn OFF when the next start signal is received.
PM8 It is used by the PLC to check if the commanded position has
definitively been reached, and also to provide a position
interlock, etc.
Moving MOVE This signal turns ON while the actuator is moving, and turns
OFF while it is stopped.
It is used for operation check and also to determine whether the
load is contacted during push & hold operation.
Position complete PEND This signal turns ON when the target position was reached and
the actuator has entered the specified in-position range.
It is used to determine whether positioning has completed.
Home return completion HEND This signal is OFF immediately after the power is input, and
turns ON when home return has completed.
Current operation mode MODES Currently enabled mode (ON: Teaching mode, OFF: Normal
mode)
Write completion WEND This signal is output upon completion of writing to the nonvolatile
memory in response to a current-position write command
(PWRT).
Ready SRDY This signal is always output once the servo is turned ON and the
controller is ready to operate.
The signal is synchronized with the lit/unlit status of the “RUN”
LED on the front panel of the enclosure.
It is used by the PLC to determine when it can start operation.
*Alarm *ALM This signal remains ON in normal conditions of use and turns
OFF when an alarm generates.
It is synchronized with the unlit/lit status of the corresponding
LED on the front panel of the enclosure.
*Emergency stop *EMGS This signal is enabled on a “built-in cutoff relay” controller.
OFF: Emergency stop has been actuated

44
z PIO pattern = “5: [4 points]
Signal
Category Signal name Function overview
abbreviation
Input Rear end move ST0 The actuator starts moving to the rear end at the rise edge of the
signal.
Front end move ST1 The actuator starts moving to the front end at the rise edge of
the signal.
Intermediate point 1 move ST2 The actuator starts moving to intermediate point 1 at the rise
edge of the signal.
Intermediate point 2 move ST3 The actuator starts moving to intermediate point 2 at the rise
edge of the signal.
*Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a
stop
Alarm reset RES An alarm is reset at a rise edge of this signal.

Output Rear end complete PE0 The signal turns ON when the actuator completes moving to the
rear end.
Front end complete PE1 The signal turns ON when the actuator completes moving to the
front end.
Intermediate point 1 PE2 The signal turns ON when the actuator completes moving to
complete intermediate point 1.
Intermediate point 2 PE2 The signal turns ON when the actuator completes moving to
complete intermediate point 2.
Zone ZONE1 This signal is output when home return has completed and the
current actuator position is inside the range set by the applicable
parameter.
It can be used as a limit switch at an intermediate point or as a
simple ruler during push & hold operation.
Position complete PEND This signal is used to determine if the controller is ready
following the power on.
The controller is ready to perform operation if an emergency
stop is not actuated, motor drive power is not cut off (= the servo
is on) and the pause signal is input.
Home return completion HEND This signal is OFF immediately after the power is input, and
turns ON when home return has completed.
*Alarm *ALM This signal remains ON in normal conditions of use and turns
OFF when an alarm generates.
It is synchronized with the unlit/lit status of the corresponding
LED on the front panel of the enclosure.
*Emergency stop *EMGS This signal is enabled on a “built-in cutoff relay” controller.
OFF: Emergency stop has been actuated

45
5.1.2 Signal Assignment Table for Respective PIO Patterns
The same signal may be assigned to a different pin number depending on the PIO pattern. Therefore,
when creating a PLC sequence or wiring the signals, refer to this table to ensure each signal is assigned
correctly.
When “4: [Teaching]” is selected, the meaning of each pin number will vary depending on the mode.
Accordingly, also pay due attention to when mode switching will occur.

Pin Category Wire color Parameter No. 25 setting

No.
0 1 2 3 4 5
Upper stage
1A +24V P24
Brown - 1
2A 0V Red - 1 N
3A Input Orange - 1 CSTR PC1 PC1 PC1 PC1 ST0
4A Yellow - 1 PC1 PC2 PC2 PC2 PC2 ST1
5A Green - 1 PC2 PC4 PC4 PC4 PC4 ST2
6A Blue - 1 PC4 PC8 PC8 PC8 PC8 ST3
7A Purple - 1 PC8 - PC16 - MODE -
8A Gray - 1 - *STP PC32 *STP *STP/JOG + *STP
9A White - 1 - CSTR CSTR CSTR CSTR/PWRT -
10A Black - 1 *STP HOME HOME HOME HOME -
11A Brown - 2 - SON *STP SON SON -
12A Red - 2 - RES RES RES RES/JOG – RES
13A Orange - 2 (Not used)
Lower stage
1B (Not used)
Yellow - 2
2B Green - 2 (Not used)
3B Output Blue - 2 PM1 PM1 PM1 PM1 PM1 PE0
4B Purple - 2 PM2 PM2 PM2 PM2 PM2 PE1
5B Gray - 2 PM4 PM4 PM4 PM4 PM4 PE2
6B White - 2 PM8 PM8 PM8 PM8 PM8 PE3
7B Black - 2 PEND ZONE1 PM16 ZONE1 MODES ZONE1
8B Brown - 3 HEND MOVE PM32 ZONE2 MOVE -
9B Red - 3 ZONE1 PEND PEND PEND PEND/WEND PEND
10B Orange - 3 *ALM HEND HEND HEND HEND HEND
11B Yellow - 3 *EMGS
12B Green - 3 - SRDY MOVE SRDY SRDY -
13B Blue - 3 - *ALM *ALM *ALM *ALM *ALM

Note:
[1] The signals indicated by * in the table (*ALM, *STP and *EMGS) are based on the negative
logic, meaning that they remain ON in normal conditions of use.
[2] Insulate the pins indicated “Not used” (13A, 1B and 2B) without connecting anything.
[3] The NPN and PNP specifications use the same power line configuration, so there is no need to
reverse the power signal assignments for a PNP controller.
[4] *EMGS (emergency-stop state) assigned to pin No. 11B is enabled on a “built-in cutoff relay”
controller.

46
5.2 Interface Circuit
The standard interface specification of the controller is NPN, but the PNP specification is also available as
an option.
To prevent confusion during wiring, the NPN and PNP specifications use the same power line
configuration. Accordingly, there is no need to reverse the power signal assignments for a PNP controller.

5.2.1 External Input Specifications

Item Specification
Number of input points 10 points
Input voltage 24 VDC ± 10%
Input current 7 mA/point
Leak current 1 mA or less/point
Insulation method Photocoupler

Internal circuit configuration

[NPN specification]
Controller

P24V Internal circuit

R = 560 Ω
External power supply R = 22 kΩ
+24V

Each input C = 0.1 µF

R = 3.3 kΩ

[PNP specification] Controller

N Internal circuit

R = 560 Ω
External power supply R = 22 kΩ
+24V

Each input C = 0.1 µF

R = 3.3 kΩ

47
5.2.2 External Output Specifications

Item Specification
Number of output points 10 points
Rated load voltage 24 VDC
Maximum current 20 mA/point
Residual voltage 2V or less
Insulation method Photocoupler

Internal circuit configuration

[NPN specification]

Controller
P24V

Load

Internal circuit Each output

Load
External power
supply
+24V

[PNP specification]
Controller

Internal circuit P24V

External power
supply
Load +24V
Each output

Load

48
5.3 Details of I/O Signal Functions
An input time constant is provided for the input signals of this controller, in order to prevent malfunction
due to chattering, noise, etc.
Except for certain signals, switching of each input signal will be effected when the signal has been
received continuously for at least 6 msec. For example, when an input is switched from OFF to ON, the
controller will only recognize that the input signal is ON after 6 msec. The same applies to switching of
input signals from ON to OFF (Fig. 1).

Input signal
Not recognized Not recognized
Recognition by controller

6 [msec] 6 [msec]

Fig. 1 Recognition of Input Signal

5.3.1. Details of Each Input Signal

„ Start (CSTR)
Upon detecting a rise (OFF → ON) edge of this signal, the controller will read the target point number as a
binary code consisting of four bits from PC1 to PC8 (or six bits from PC1 to PC32 in the 64-point
positioning pattern), and execute positioning to the target position of the corresponding position data.
Before issuing a start command, all operation parameters such as the target position and speed must be
set in the nonvolatile memory of the controller.
If a start command is issued when home return operation has not been performed yet after the power was
input (the HEND output signal is OFF), the controller will automatically perform home return operation
before positioning to the target position.

„ Command position number (PC1 to PC32)

When a movement command is effected upon OFF → ON of the start signal, the six-bit binary code
consisting of signals PC1 to PC32 will be read as the command position number.
(Only with an expanded controller the binary code consists of six bits from PC1 to PC32. The binary code
for all other controller types consists of four bits from PC1 to PC8.)
The weight of each bit is as follows: 20 for PC1, 21 for PC2, 22 for PC4, 23 for PC8, 24 for PC16 and 25 for
PC32. A desired position number from 0 to 63 (maximum) can be specified.

„ Pause (*STP)
When this signal turns OFF while the actuator is moving, the actuator will decelerate to a stop.
The remaining movement is retained and will be resumed when the signal is turned ON again.
To abort the movement command, turn ON the alarm reset signal while this signal is OFF to cancel the
remaining movement.
The *STP signal can be used for the following purposes:
[1] Provide a low-level safety measure to stop the axis while the servo is ON, such as a sensor that
detects a person approaching the system
[2] Prevent contact with other equipment
[3] Perform positioning based on sensor or LS detection
(Note) If the *STP signal is input while the actuator is performing home return, the movement command
will be retained if the actuator is yet to contact a mechanical end. If the signal is input after the
actuator has reversed upon contacting a mechanical end, home return will be performed again
from the beginning.

49
„ Home return (HOME)
The controller will start home return operation upon detection of an OFF → ON edge of this signal.
When the home return is complete, the HEND signal will be output. The HOME signal can be input as
many times as required.
(Note) The HOME signal is not an absolute requirement, because even if home return has not yet been
performed after the power was input, the controller will automatically perform home return
operation before positioning to the target position.
Setting “0.00 mm” as the position data will allow for movement to the home. Still, the HOME
signal is convenient when there is no space in the position-data table or when the controller is
used in the teaching mode.

„ Servo ON (SON)
The servo remains ON while this signal is ON.
Use this signal if servo ON/OFF control must be performed by the PLC as part of a safety circuit covering
the entire system.
Parameter No. 21 that defines whether to enable or disable this signal must always be set.
Set “0: [Enable]” if the SON signal is used, or “1: [Disable]” if the signal is not used.
(Note) If the SON signal is turned OFF during movement in case of error, the actuator will decelerate to
a stop at the emergency-stop torque and then the servo will turn OFF.

„ Alarm reset (RES)

This signal provides two functions.
[1] Reset the alarm output signal (*ALM) that turned OFF due to an alarm
If an alarm has generated, turn ON this signal after confirming the nature of the alarm.
The controller will reset the alarm upon detection of a rise edge of the RES signal.
(Note) Certain alarms cannot be reset by the RES signal. For details, refer to 10, “Troubleshooting.”
[2] Cancel the remaining movement when the pause signal is OFF
This function is used when the remaining movement must be cancelled to allow for incremental
moves (movements at a constant increment) from the position where the actuator stopped following a
sensor detection.

„ Operation mode (MODE)

This signal is enabled when parameter No. 25 is set to “4: [Teaching].”
Turning the MODE signal ON will switch the normal operation mode to the teaching mode.
(Note) For the mode switching to occur, all of the *STP, CSTR and RES input signals must be OFF.
Once the mode switches, the MODES output signal will turn ON.
Configure the system in such a way that the PLC will accept a PWRT, JOG+ or JOG- operation
command after confirming the ON status of the MODES output signal.
Turn the MODE signal OFF to return to the normal operation mode.
Configure the system in such a way that the PLC will accept a command in the normal operation
mode after confirming the OFF status of the MODES output signal.
(Note) The normal operation mode cannot be restored unless all of the PWRT, JOG+ and JOG- input
signals are OFF.

50
„ Current-position write (PWRT)
This signal is enabled when the aforementioned MODES output signal is ON.
If the PWRT signal has remained ON for 20 msec or longer, the controller will read the position number
specified by the currently detected binary code consisting of PC1 to PC8, and write the current position
data as the target position in the corresponding position data.
If data other than the target position (speed, acceleration/deceleration, positioning band, etc.) are yet to be
defined, the default parameter settings will be written.
When the writing completes successfully, the WEND output signal will turn ON.
Configure the system in such a way that the PLC will turn OFF the PWRT signal when WEND turns ON.
The controller will turn OFF WEND once the PWRT signal turns OFF.
(Note) An alarm will generate if a write command is issued when home return has not been performed
yet or while the actuator is moving.
• Condition for PWRT to be enabled when the servo is ON:
The PWRT signal is enabled when both the JOG+ and JOG- input signals are OFF, HEND
output signal is ON and MOVE output signal is OFF.
• Condition for PWRT to be enabled when the servo is OFF:
The PWRT signal is enabled when the HEND output signal is ON, but whether the actuator is
being moved by hand or stopped cannot be determined from HEND alone. Input the PWRT
signal when the operation is stopped.

„ Jog (JOG+, JOG-)

These signals are enabled when the aforementioned MODES output signal is ON.
The controller will move the actuator to the +/- soft limit upon detection of a rise (OFF → ON) edge of each
JOG signal.
When the soft limit is reached, the actuator will be forced to decelerate to a stop without generating an
alarm.
The speed and acceleration/deceleration set in parameter No. 26 (PIO jog speed) and No. 9 (Default
acceleration/deceleration) will be used.
The actuator will not move if both the JOG+ and JOG- signals are turned ON. If both signals are turned
ON while the actuator is moving, the actuator will decelerate to a stop.
The controller will decelerate the actuator to a stop upon detection of a fall (ON → OFF) edge of each
JOG signal.
(Note) Executing jogging before home return is completed may disable the soft limits and cause the
actuator to crash into a mechanical end, so exercise due caution.

„ Movement to each position (ST0 to ST3)

The number of positioning points is limited to four, so the RCP2 can be controlled just like an air cylinder.
When the OFF Æ ON rise edge of each movement signal is detected, the actuator will move to the target
position corresponding to the applicable position data.
Before executing a command using any of these signals, make sure the target position, speed and other
operation data are set in the position table using a PC or teaching pendant.

Corresponding
Remarks
position number
Rear end move (ST0) 0 Set the rear end position in position No. 0.
Front end move (ST1) 1 Set the front end position in position No. 1.
Intermediate point 1 move (ST2) 2 Set the position of intermediate point 1 in position No. 2.
Intermediate point 2 move (ST3) 3 Set the position of intermediate point 2 in position No. 3.

If a movement command is issued when the first home return is not yet completed after the power was
input, home return will be performed automatically to establish the coordinates first, after which the
actuator will move to the target position.

51
5.3.2 Details of Each Output Signal

„ Completed position number (PM1 to PM32)

These signals can be used to check the completed position number when the PEND signal turns ON.
The signals are output as a binary code.
Immediately after the power is input, all of the PM1 to PM32 signals are OFF.
(Only with an expanded controller the binary code consists of six bits from PM1 to PM32. The binary code
for all other controller types consists of four bits from PM1 to PM8.)
All of PM1 to PM32 are OFF also when the actuator is moving.
As described above, this signal is output only when positioning is completed.
(Note) All of PM1 to PM32 will turn OFF when the servo is turned OFF or an emergency stop is
actuated. They will return to the ON status when the servo is turned ON again, provided that the
current position is inside the in-position range with respect to the target position. If the current
position is outside the range, the signals will remain OFF.
When the power is input, the PEND signal will turn ON. Since PM1 to PM32 are all OFF, this
condition is the same as one achieved after positioning to position “0” is completed.
Check the position of position 0 after the movement command has completed.
If an alarm is present, the corresponding alarm code (abbreviated form) consisting of four bits from PM1 to
PM8 will be output.
The meanings of these signals vary between the normal condition and the alarm condition, so be careful
not to use them wrongly in the sequence.

„ Moving (MOVE)
This signal is output while the servo is ON and the actuator is moving (also during home return, push &
hold operation or jogging).
Use the MOVE signal together with the PEND signal to allow the PLC to determine the actuator status.
The MOVE signal will turn OFF after positioning or home return is completed or a judgment is made
during push & hold operation that the load is being contacted.

„ Position complete (PEND)

This signal indicates that the target position was reached and positioning has completed.
Use the PEND signal together with the MOVE signal to allow the PLC to determine the positioning status.
When the controller becomes ready after the power was input and the servo has turned ON, this signal will
turn ON if the position deviation is within the in-position range.
Then, when a movement command is issued by turning ON the start signal, the PEND signal will turn
OFF. It will turn ON again when the deviation from the target position falls within the in-position range.
Once turned ON, the PEND signal will not turn OFF even when the position deviation subsequently
exceeds the in-position range.
(Note) If the start signal remains ON, the PEND signal will not turn OFF even when the deviation from
the target position falls within the in-position range: it will turn ON when the start signal turns
OFF.
Even when the motor is stopped, the PEND signal will remain OFF if the pause signal is input or
the servo is OFF.

„ Home return completion (HEND)

This signal is OFF immediately after the power is input, and turns ON in either of the following two
conditions:
[1] Home return operation has completed with respect to the first movement command issued with the
start signal.
[2] Home return operation has completed following an input of the home return signal.

52
Once turned ON, the HEND signal will not turn OFF unless the input power supply is cut off, a soft reset is
executed, or the home return signal is input again.
The HEND signal can be used for the following purposes:
[1] Check prior to establishing the home if movement toward the home direction is permitted, in cases
where an obstacle is located in the direction of the home
[2] Use as a condition for writing the current position in the teaching mode
[3] Use as a condition for enabling the zone output signal

„ Zone (ZONE1, ZONE2)

Use a ZONE signal as a limit switch at an intermediate point or as a simple ruler.
The ZONE1 signal will turn ON when the current position is inside the range specified by parameter Nos.
1 and 2, and turn OFF if the current position is outside this range.
(If the 2 zone output signals pattern is selected, the ZONE2 signal will turn ON/OFF in the same manner
with respect to the range specified by parameter Nos. 23 and 24.)
(Note) The ZONE signals are enabled after the coordinate system is established following a completion
of home return. They will not be output simply by turning on the power.
As long as home return has completed, the ZONE signals remain enabled while the servo is
OFF or during an emergency stop.

„ Current operation mode (MODES)

This signal is enabled when the teaching pattern is selected.
The MODES signal will turn ON when the teaching mode is enabled upon selection of the teaching mode
via the operation mode input signal (MODE signal ON).
Thereafter, the MODES signal will remain ON until the MODE signal turns OFF.
Configure the system in such a way that the PLC will start teaching operation after confirming that the
MODES signal has turned ON.

„ Write completion (WEND)

This signal is enabled only when the teaching pattern is selected.
The WEND signal is OFF immediately after the controller has switched to the teaching mode. It will turn
ON when the writing of position data in response to the current-position write signal is completed.
When the current-position write signal turns OFF, this signal will also turn OFF.
Configure the system in such a way that the PLC will acknowledge completion of writing when the WEND
signal turns OFF.

„ Completion of each position (PE0 to PE3)

The number of positioning points is limited to four, so the RCP2 can be controlled just like an air cylinder.
These signals indicate that the target position corresponding to each movement command (ST0, ST1,
ST2 or ST3) has been reached, in the same way the reed switch signal does for an air cylinder.
Output signal Meaning of the signal
The actuator has reached and stopped at the rear end (target position set in
Rear end complete (PE0)
position No. 0).
The actuator has reached and stopped at the front end (target position set in
Front end complete (PE1)
position No. 1).
Intermediate point 1 The actuator has reached and stopped at intermediate point 1 (target position set
complete (PE2) in position No. 2).
Intermediate point 2 The actuator has reached and stopped at intermediate point 2 (target position set
complete (PE3) in position No. 3).

Note) These signals turn OFF when the servo is turned OFF or an emergency stop is actuated. They
will return to the ON status when the servo is turned ON again, provided that the current position
is inside the in-position range with respect to the target position. If the current position is outside
the range, the signals will remain OFF.

53
„ Ready (SRDY)
This is a monitor signal indicating that the servo is ON and the motor is ready.
The ON/OFF status of the SRDY signal is synchronized with the lit/unlit status of the “RUN” LED on the
front panel of the enclosure.
Use this signal as a condition for starting a movement command on the PLC side.
Refer to 7.1, “How to Start,” for the timing to issue this signal after the power is input.

„ Alarm (*ALM)
This signal remains ON while the controller is operating properly, and turns OFF when an alarm has
generated.
Provide an appropriate safety measure for the entire system by allowing the PLC to monitor the OFF
status of this signal.
For details of alarms, refer to 10, “Troubleshooting.”

„ Emergency stop (*EMGS)

This signal is enabled on a “built-in cutoff relay” controller.
The *EMGS signal remains ON in normal conditions of use, and turns OFF when the emergency-stop
switch has been pressed.
Provide an appropriate safety measure for the entire system by allowing the PLC to monitor the OFF
status of this signal.

(Reference) Output Signal Changes in Each Mode

Mode classification MOVE PEND SRDY HEND PM1-PM8

Actuator is stopped with the servo ON after the power was
OFF ON ON OFF OFF
input
Home return is in progress following an input of the home
ON OFF ON OFF OFF
return signal
Home return has completed following an input of the home
OFF ON ON ON OFF
return signal
Actuator is moving in the positioning/push & hold mode ON OFF ON ON OFF
Actuator is paused in the positioning/push & hold mode OFF OFF ON ON OFF
Positioning has completed in the positioning mode OFF ON ON ON ON
Actuator has stopped after contacting the load in the push &
OFF ON ON ON ON
hold mode
Actuator has stopped after missing the load (no load) in the
OFF OFF ON ON ON
push & hold mode
Actuator is stopped with the servo ON in the teaching mode OFF ON ON
Actuator is jogging in the teaching mode ON ON ON
Actuator is being moved by hand with the servo OFF in the
OFF OFF ON
teaching mode
Servo is OFF after home return OFF OFF OFF ON OFF
Emergency stop has been actuated after home return OFF OFF OFF ON

(Note) Determine whether the actuator has stopped after contacting the load or missing the load from
the signal statuses of MOVE, PEND and PM1 to PM8.

54
6. 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 the target position in the position-data table, and the actuator will move to the
specified position.
Position data consists of number (No.), target 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.
The target position 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

55
6.1 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) Target position • Enter the target position to move the actuator to, in [mm].
(Position) Absolute mode: Enter the distance to the target actuator position from
the home.
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/ • Enter the acceleration/deceleration at which the actuator will be moved,
deceleration (ACC) in [G].
The default value varies depending on the actuator type.

Speed

Acceleration/deceleration (ACC)

Start Completion Time

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

MAX 1.00 G (Quick rise) (The maximum
acceleration/deceleration G is set to 0.6 G on some models.)

(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 [%]
• To select the push & hold mode, enter the current-limiting value for the
servo motor during push & hold operation. Enter an appropriate value up
to 70% in accordance with the actuator type.

Be sure to refer to 6.1.1, “Relationship of Push Force at Standstill and

Current-Limiting Value” that specifies the relationship of the push force to
be applied to the load at standstill [kgf] on one hand, and the current-
limiting value on the other, for each actuator type.

56
 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.
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

set in (4) set in (4)

Maximum acceleration

Moving distance Moving distance

57
6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value
When performing operation in the push & hold mode, enter the current-limiting value (%) in the push
column of the position-data table.
Determine the current-limiting value (%) from the push force to be applied to the load at standstill.
The graphs below illustrate the relationship of push force at standstill and current-limiting value for each
actuator type:

(1) RPA type

100
Push force (N) 80
60
40
20
0
10 20 30 40 45
Current-limiting value (%)

(2) RXA type

Low-speed type Medium-speed type

(Lead: 2.5 mm) (Lead: 5 mm)
180 80
160 70
140 60
120
Push force (N)
Push force (N)

50
100
40
80
30
60
40 20
20 10
0 0
20 30 40 50 60 70 20 30 40 50 60 70
Current-limiting value (%) Current-limiting value (%)

Maximum current-limiting value

Low-speed type 70%
Medium-speed type 70%

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for
reference purposes only. If the push force is too small, malfunction may occur during push &
hold operation due to slide resistance, etc., so exercise caution.
The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

58
(3) RSA type

Low-speed type Medium-speed type

(Lead: 2.5 mm) (Lead: 5 mm)

400 400
Push force (N)

Push force (N)

300 300
200 200
100 100
0 0
20 30 40 50 20 30 40 50 60 70
Current-limiting value (%) Current-limiting value (%)

High-speed type
(Lead: 10 mm)

200
Push force (N)

150 Maximum current-limiting value

100 Low-speed type 50% or less

50 Medium-speed type 70% or less

High-speed type 70% or less
0
20 30 40 50 60 70

Current-limiting value (%)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for
reference purposes only. If the push force is too small, malfunction may occur during push &
hold operation due to slide resistance, etc., so exercise caution.
The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

59
(4) RMA type

Low-speed type Medium-speed type

(Lead: 4 mm) (Lead: 8 mm)
900 500
800
400

Push force (N)

700
Push force (N)

600
500 300
400
300 200
200 100
100
0 0
20 30 40 50 60 65 20 30 40 50 60 70
Current-limiting value (%) Current-limiting value (%)

High-speed type
(Lead: 16 mm)
300
Push force (N)

250
200 Maximum current-limiting value
150
Low-speed type 65%
100
50 Medium-speed type 70%
0 High-speed type 70%
20 30 40 50 60 70

Current-limiting value (%)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for
reference purposes only. If the push force is too small, malfunction may occur during push &
hold operation due to slide resistance, etc., so exercise caution.
The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

60
(5) RFA type

Low-speed type Medium-speed type

(Lead: 2.5 mm) (Lead: 5 mm)
Push force (N)

Push force (N)

Current-limiting value (%) Current-limiting value (%)

High-speed type
(Lead: 10 mm)

Maximum current-limiting value

Push force (N)

Low-speed type 70%

Medium-speed type 70%
High-speed type 70%

Current-limiting value (%)

Note: The accuracy of push force at standstill is not guaranteed. The above graphs are provided for
reference purposes only. If the push force is too small, malfunction may occur during push &
hold operation due to slide resistance, etc., so exercise caution.
The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

61
6.2 Explanation of Modes
6.2.1 Positioning Mode Push = 0

Position complete signal

Speed

Completed position number (1) The position complete output will turn
ON at a position preceding the target
Output
position by the positioning band. A
completed position number signal will
be output at the same time.

Moving distance
Positioning band

6.2.2 Push & Hold Mode Push = Other than 0

(1) Load was contacted successfully

Position complete signal (1) After reaching the target position, the
Completed position number
Speed

actuator will move at low speed.

Output
When the Pos. band set in the data
table (see Note) is reached after the
actuator contacts the load and the
stepper motor current has reached the
current-limiting value, the position
complete output will turn ON. A
Moving distance Positioning band completed position number signal will be
output at the same time.
Note: Set 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

62
(2) Load was not contacted (missed)

(1) After reaching the target position, the

Completed position number actuator will move at low speed.
Speed

Even after contacting the load, the

Output actuator will move to the end of the
positioning band if the stepper motor
current is yet to reach the current-
limiting value.
The position complete output will not
Moving distance turn ON even when the end of the
Positioning band positioning band is reached. In this
case, only the completed position
number will be output. (Provide a
timeout check process after a sufficient
period with a PLC.)

(3) Load moves during push & hold operation

(a) Load moves in the pushed direction

Position complete signal If the load moves in the pushed direction

Completed position number after the position complete output has
Speed

turned ON, the actuator will push the

Output load within the positioning band.
If the current drops below the limiting
value, the position complete signal will
turn OFF. The signal will turn ON when
Moving distance the current rises to or above the limiting
value.
Positioning band

(b) Load moves in the opposite direction

(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

Output than 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. The position
Moving distance complete output will remain ON and the
completed position number will be
output continuously.

63
(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

6.2.3 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

6.2.4 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

64
6.2.5 Pause
The actuator can be paused during movement using an external input signal (*pause).
The pause signal uses the contact B logic (always ON) to ensure safety.
Turning OFF the *pause input will cause the actuator to decelerate to a stop, while turning it ON will allow
the actuator to complete the remaining operation.

ON ON
*Pause signal OFF

Actuator operation
Target position

(Note) During deceleration, the acceleration/deceleration set in the position table under the currently
executed position number is used.

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

Note) If parameter No. 25 (IO pattern) is set to “0: [Conventional],” the reset input is not available.

65
6.2.6 Zone Signal Output
A signal will be output when the actuator enters the specified zone.
The zone signal will turn ON when the actuator enters the zone predefined by the applicable parameters.
(The zone can be set arbitrarily.)

Zone signal

Actuator operation

Zone signal setting range

If parameter No. 25 is set to “3: [2 zone output signals],” two zone output signals can be set. The second
zone value is set by parameter No. 23 (Zone 2+) and No. 24 (Zone 2-).
Note) The zone signal output function is not available if parameter No. 25 (PIO pattern) is set to “2: [64-
point positioning]” or “4: [Teaching].”

6.2.7 Home Return

(1) On the standard controller, home return must be executed after the power is turned on to establish
the home.
(2) On the absolute controller, home return is not required when the power is turned on. This is because
once home return is executed, the current position will be retained even after the power is turned off.
On the absolute controller, home return is required only after the controller is started for the first time
or when the current position has been lost due to low battery voltage, etc.

There are two ways to execute home return.

z Not using the dedicated input [PIO pattern = 0 (Conventional) or 5 (4 points)]
If home return has not been executed yet, inputting a command position followed by the start signal will
execute home return.

z Using the dedicated input [PIO pattern = Other than 0 (Conventional) or 5 (4 points)]
Inputting the home return signal (HOME) will execute home return regardless of whether the home
position has already been established or nor.

+ Ì For details, refer to 7.2, “How to Execute Home Return.”

66
6.2.8 Teaching Mode (Jogging/Teaching Using PIO)
The actuator can be jogged using PIO if parameter No. 25 (PIO pattern) is set to “4: [Teaching].” The
current actuator position can also be read into the controller’s position-data table using PIO.
Switching between the normal positioning mode (including the push & hold mode) and the teaching mode
is implemented by turning ON/OFF the operation mode input. Among the PIO signals, the +jog and
*pause inputs, –jog and reset inputs, current-position write and start inputs, and write completion and
position complete outputs use the same terminal, respectively, and are toggled in accordance with
ON/OFF of the operation mode input.

Operation mode input ON OFF

Mode Teaching mode Positioning mode
+Jog input *Pause input
–Jog input Reset input
PIO
Current-position write input Start input
Write completion output Position complete output

Among the PIO signals, use the +jog/–jog inputs to move the actuator, and use the current-position write
input to write the current actuator position to the position-data table. When the writing is complete, the
write completion output will turn ON.
+ For details, refer to 7.12, “Jogging/Teaching Using PIO.”

Note: Be sure to enable the pause signal using parameter No. 15 (by setting the parameter to “0”)
(the pause signal is enabled at the factory). The system cannot switch to the teaching mode if
the pause signal is disabled (i.e., the above parameter is set to “1”).

67
6.2.9 Overview of the “4 Points” (Air Cylinder) Mode
This mode provides a control method adjusted to that of an air cylinder by assuming that the RCP2 is
used as an air cylinder.
The key differences between the RCP2 and an air cylinder are summarized below. Perform proper control
by referring to this table.
Item Air cylinder RCP2
Drive method Air pressure supplied via Ball screw/timing belt driven by a motor
electromagnetic valve
control
Target Mechanical stopper Desired coordinates are entered in the [Target position] field
position (including shock absorber) of the position table.
setting The coordinates can be typed in from the number keys on the
PC keyboard or on the teaching pendant, or set directly by
moving the actuator to the target position.
Target An external detection Determined based on the internal coordinates provided by the
position sensor, such as a reed position information from the position detector (encoder).
detection switch, is installed. Accordingly, external detection sensor is not required.
Speed setting Adjusted by a speed A desired feed speed is entered in the [Speed] field of the
controller. position table (unit: mm/sec).
Note that the rated speed is automatically set as the initial
value.
Acceleration/ Determined in accordance A desired acceleration/deceleration is entered in the
deceleration with the load, supplied air [Acceleration/deceleration] field of the position table (unit:
setting volume, as well as the 0.01 G).
performance of the speed (Reference) 1 G = Gravitational acceleration
controller and Note that the rated acceleration/deceleration is automatically
electromagnetic valve. set as the initial value.
Since the acceleration/deceleration can be set in fine steps, a
gradual acceleration/deceleration curve can be programmed.
Position Determined by an external Immediately after the power is turned on, the controller
check upon detection sensor, such as cannot identify the current position because the mechanical
power ON a reed switch. coordinates have been lost.
Therefore, when the first movement command is issued after
the power has been input, the controller will automatically
perform home return before moving the actuator to the target
position.
[1]

[2]
Power is turned
[3] on here.
Home position
Target position
[1] The actuator moves at the home return speed toward the
mechanical end on the motor side.
[2] The actuator hits the mechanical end and turns back, and
then stops temporarily at the home position.
[3] The actuator moves to the target position at the speed
specified in the [Speed] field of the position table.
(Note) Pay attention not to allow any obstacle in the travel
path of the actuator during home return.

68
The relationships of movement command inputs/position complete outputs and corresponding position
numbers are shown below.
For easier identification, each input/output signal has a name similar to the naming convention used with
air cylinders.
However, note that the target position is determined by the value set in the [Target position] field under
each position number. Therefore, changing the magnitude correlation of the settings in Nos. 0 to 3 will
change the meanings of the corresponding input/output signals.
Accordingly, the settings in the respective position numbers should match the semantic meanings of the
corresponding signal names used in this operation manual, unless doing so will pose a problem.

Input signal Output signal Target position

Setting in the [Target position] field under
Rear end move (ST0) Rear end complete (PE0)
position No. 0 Example: 5 mm
Setting in the [Target position] field under
Front end move (ST1) Front end complete (PE1)
position No. 1 Example: 390 mm
Setting in the [Target position] field under
Intermediate point 1 move (ST2) Intermediate point 1 complete (PE2)
position No. 2 Example: 100 mm
Setting in the [Target position] field under
Intermediate point 2 move (ST3) Intermediate point 2 complete (PE3)
position No. 3 Example: 250 mm

z Positioning relationship on the Robo Cylinder

An example of a slider type with a stroke of 400 mm is explained.

[Motor side] [Counter-motor side]

Home position (0 mm) Front end complete (390 mm)

Rear end complete (5 mm) Intermediate point 2 complete (250 mm)

Intermediate point 1 complete (100 mm)

z Position table (Enter in the fields indicated in bold)

Acceleration/de Positioning Acceleration

No. Position Speed Push
celeration band only MAX
0 5 500 0.3 0 0.1 0
1 390 500 0.3 0 0.1 0
2 100 500 0.3 0 0.1 0
3 250 500 0.3 0 0.1 0

69
6.3 Notes on the Robo Gripper (GRS/GRM)
(1) Finger operation
[1] Definition of position
The stroke in the specification represents the sum of travels of both fingers.
Therefore, the travel of one finger is one-half the stroke.
The position is specified as a travel of one finger from the home toward the closing side.
Accordingly, the maximum command value is 5 mm for the GRS type and 7 mm for the GRM
type.

[2] Definition of speed and acceleration

The command value applies to each finger.
Therefore, the relative speed and acceleration are twice their respective command values.

[3] Operation mode in gripper applications

When the actuator is used to grip the load, be sure to select the “push & hold mode.”
(Note) In the “positioning mode,” a servo error may occur while the load is gripped.

[Diagrams of gripping force and current-limiting value]

Gripping force (N)

Gripping force (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

(2) Removing the gripped load

This gripper is designed to maintain the load-gripping force via a self-lock mechanism even when the
servo is turned OFF or the controller power is cut off.
If the gripped load must be removed while the power is cut off, do so by turning the open/close screw
or removing the finger attachment on one side.

Finger attachment

Open/close screw
Turn the screw counterclockwise
using a flathead screwdriver.
direction
Opening

Affixing bolt

70
71
7. Operation <Practical Steps>
7.1 How to Start
7.1.1 Standard Specification
(1) Connect the motor cable 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 address switch. For details,
refer to 9, “Controlling Multiple Controllers via Serial Communication.”
(4) Actuate an emergency stop or cut off the motor power.
(5) Supply 24 VDC to the controller’s terminal block.
(6) Confirm that the slider or rod is not contacting the mechanical end.
If the slider or rod is contacting the mechanical end, or when the slider/rod is not contacting the
mechanical end but is located near the home, move the slider/rod away from the home.
If the actuator is equipped with a brake, move the slider/rod after turning ON the brake release switch
to forcibly release the brake. At this time, exercise caution not to allow the load to drop suddenly due
to its own weight. Your hand may be caught by the dropped load or the robot hand or load itself may
be damaged.

If the servo is turned ON while the slider/rod is contacting the mechanical end, excitation
Warning phase detection may not be performed correctly and an abnormal operation or excitation
detection error may result.

(7) Connect a PC or teaching pendant and set the following parameters as the minimum initial settings:
• Parameter No. 15, “Pause input disable selection”
• Parameter No. 21, “Servo ON input disable selection”
• Parameter No. 25, “PIO pattern selection”
• Parameter No. 27, “Movement command type” (when “4 points” is selected)
For details, refer to 8, “Parameters.”
(8) Cancel the emergency stop or supply the motor power.
Ì The ALM lamp will turn off.
(9) Input a pause signal (*STP) and a servo ON signal (SON) from the PLC (if these signals are
enabled).
Ì The controller servo will turn ON and the RUN lamp (LED) will illuminate.
Ì The position complete output (PEND) and ready output (SRDY) will also turn ON.
+ If the ALM lamp is lit, there is an error. Refer to the alarm table and take an appropriate action.
(10) Perform home return.
z Overview of operation on the teaching pendant
• On the RCA-T, select the “Edit/Teach” screen, bring the cursor to “*Home” in the sub display
area, and then press the Return key.
• On the RCA-E, select the “Teach/Play” screen, scroll until “*Home Return” is displayed, and
then press the Return key.
• On the RCB-J, the “Operation Key → Home Return” screen will be displayed automatically.
Press the Operation key on this screen.

72
 z Overview of operation on the PC software
Select an applicable position data in the main window, and then click the [Home] button.
For details, refer to the operation manual for the teaching pendant or PC software.
z Issuing a command from the PLC
Perform signal processing appropriate for the selected PIO pattern by referring to 7.2.1, “Standard
Specification.”
Issue a command after confirming that the position complete signal (PEND) has
turned ON.
If home return cannot be performed, confirm that the *pause signal and servo ON signal are ON and
that the safety circuit is released, and also check if any error message is displayed.

(11) Set the target position, speed, acceleration/deceleration, positioning band and other data in the
position table. For details on how to set these data, refer to the operation manual for the teaching
pendant/PC software.

Now, automatic operation can be performed via PLC link.

Timing chart at startup

Emergency stop is actuated or

Safety circuit condition motor drive power is cut off Emergency stop is not actuated
or motor drive power is supplied

24-VDC power ON
Initial parameter settings

ALM lamp

*Pause input
Pause is cancelled
(STP)

Servo ON input
(SON)

RUN lamp Lit

Ready output
(SRDY)

Position complete output

(PEND)

Home return completion output

(HEND)
Start of movement

Mechanical end

Home position

Home return operation

Creation of position table using the

teaching pendant or PC operation

Note: If parameter No. 25 (PIO pattern) is set to “0: [Conventional],” “2: [64-point positioning]”
or “5: [4 points],” the servo ON input and ready output are not provided.

73
7.1.2 Absolute Specification (Absolute Reset)
(1) Connect the motor cable 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 address of each axis using the address switch. For details,
refer to 9, “Controlling Multiple Controllers via Serial Communication.”
(4) Actuate an emergency stop or cut off the motor drive power.
(5) Connect the battery connector.
(6) Supply 24 VDC to the controller’s terminal block.
Ì The alarm output signal (*ALM) will turn OFF, the alarm code output signals (PM8 to PM1) will
indicate “1101,” and the ALM lamp will illuminate.
The message “Absolute encoder error (2)” will be displayed on the PC/teaching pendant, if
connected.
(7) Confirm that the slider or rod is not contacting the mechanical end.
If the slider or rod is contacting the mechanical end, or when the slider/rod is not contacting the
mechanical end but is located near the home, move the slider/rod away from the home.
If the actuator is equipped with a brake, move the slider/rod after turning ON the brake release switch
to forcibly release the brake. At this time, exercise caution not to allow the load to drop suddenly due
to its own weight. Your hand may be caught by the dropped load or the robot hand or load itself may
be damaged.

If the servo is turned ON while the slider/rod is contacting the mechanical end, excitation
Warning phase detection may not be performed correctly and an abnormal operation or excitation
detection error may result.

(8) Connect a PC or teaching pendant and set the following parameters as the minimum initial settings:
• Parameter No. 15, “Pause input disable selection”
• Parameter No. 21, “Servo ON input disable selection”
• Parameter No. 25, “PIO pattern selection”
• Parameter No. 27, “Movement command type” (when “4 points” is selected)
For details, refer to 8, “Parameters.”
(9) Reset the alarm.
z Using the teaching pendant
• On the RCA-T/RCA-E, press the BEGIN/END key.
• On the RCB-J, press the Stop key.
z Using the PC software
Select an applicable position data in the main window, and then click the [Alarm] button.
z Issuing a command from the PLC
• If the PIO pattern is set to “0: [Conventional],” input a start signal (CSTR) for 6 msec or longer.
• If the PIO pattern is set to a value other than “0: [Conventional],” input a reset signal (RES) for 6
msec or longer.

Ì The message “Absolute encoder error (2)” will be cleared.

The alarm output signal (*ALM) will turn ON and the alarm code output signals (PM8 to PM1)
will turn OFF.

(10) Cancel the emergency stop or supply the motor drive power.
Ì The ALM lamp will turn off.

74
(11) Input a pause signal (*STP) and a servo ON signal (SON) from the PLC (if these signals are
enabled).
Ì The controller servo will turn ON and the RUN lamp (LED) will illuminate. The position complete
output (PEND) and ready output (SRDY) will also turn ON.
Ì If the ALM lamp is lit, there is an error. Refer to the alarm table and take an appropriate action.
(12) Perform home return.
z Overview of operation on the teaching pendant
• On the RCA-T, select the “Edit/Teach” screen, bring the cursor to “*Home” in the sub display
area, and then press the Return key.
• On the RCA-E, select the “Teach/Play” screen, scroll until “*Home Return” is displayed, and
then press the Return key.
• On the RCB-J, the “Operation Key → “Home Return” screen will be displayed automatically.
Press the OPERATION key on this screen.
z Overview of operation on the PC software
Select an applicable position data in the main window, and then click the [Home] button.

For details, refer to the operation manual for the teaching pendant or PC software.

z Issuing a command from the PLC

Perform signal processing appropriate for the selected PIO pattern by referring to 7.2.2,
“Absolute Specification.”

Issue a command after confirming that the position complete signal (PEND) has turned ON.

If home return cannot be performed, confirm that the *pause signal and servo ON signal are ON
and that the safety circuit is released, and also check if any error message is displayed.

When home return completes, the home position will be established and stored in the position data.
This position data will be backed up by the battery even after the power is cut off. Therefore, home
return need not be performed after the power is reconnected.
Note, however, that the battery retention period is approx. 250 hours after the power is cut off. If the
controller is not operated for a longer period such as in a case where the equipment is exported
overseas, the battery voltage will drop and the stored position data will be lost.
If the position data is lost, an “Absolute encoder error (2)” alarm will occur the next time the power is
turned on. If this alarm occurs, follow the same steps to reset the alarm and perform home return.
Also, keep the power supplied for at least 48 hours to charge the battery.

(13) Set the target position, speed, acceleration/deceleration, positioning band and other data in the
position table.
For details on how to set these data, refer to the operation manual for the teaching pendant/PC
software.

Now, automatic operation can be performed via PLC link.

75
Timing chart at startup

Emergency stop is actuated or

Safety circuit condition Emergency stop is not actuated
motor drive power is cut off
or motor drive power is supplied

24-VDC power ON * Keep the power supplied for

Initial parameter settings at least 48 hours to charge
the battery.

Resetting the alarm

• RCA-T/E: Press the
BEGIN/END key.
• RCB-J: Press the STOP key.
• PC software: Click the [Alarm]
button.
• PLC command: Start signal
(CSTR)/reset signal (RES) 6 msec or more

Alarm output
(*ALM)
Alarm code output
(PM8~PM1)

ALM lamp

*Pause input
Pause is cancelled
(STP)

Servo ON input
(SON)

RUN lamp Lit

Ready output
(SRDY)

Position complete output

(PEND)

Home return completion output

(HEND)
Start of movement

Mechanical end

Home position

Home return operation

Creation of position table using the

teaching pendant or PC operation

Note: If parameter No. 25 (PIO pattern) is set to “0: [Conventional],” “2: [64-point positioning]”
or “5: [4 points],” the servo ON input and ready output are not provided.

76
7.2 How to Execute Home Return
First, force the position complete signal to turn ON by referring to 7.1, “How to Start.”

7.2.1 Standard Specification

z When the PIO pattern is “0: [Conventional]”
Select and input a desired command position number in which a target position is registered, and then
input the start signal.
Home return is executed first, and then the actuator moves to the target position.
The home return completion (HEND) will turn ON at the home position, and upon reaching the target
position the position complete (PEND) and completed position output (PM1 to PM8) will turn ON.
To stop the actuator at the home position, set the target position to “0.”

z When the PIO pattern is “5: [4 points]”

Input the movement command to one of the four positions (ST0 to ST3).
Home return is executed first, and then the actuator will move to the target position.
The home return completion signal (HEND) will turn ON at the home position, and upon reaching the
target position the position complete signal (PEND) and the complete signal for each corresponding
position (PE1 to PE3) will turn ON.
To stop the actuator at the home position, set the target position to “0” in position No. 0 (Rear end), and
then input the rear end move signal (ST0).

z When the PIO pattern is other than “0: [Conventional]” or “5: [4 Points]”
Input the home return signal (HOME).
When home return is complete, the home return completion (HEND) and position complete (PEND) will
turn ON.

77
7.2.2 Absolute Specification
Home return must be executed when the controller is started for the first time. Even after the home has
been established, home return will become necessary if the current position is lost due to low battery
voltage, etc.
If the home return completion (HEND) is OFF when the power is input, check the cause and then reset the
alarm to turn the alarm output (*ALM) ON.
Next, be sure to execute home return and confirm that the home return completion (HEND) will turn ON.

z When the PIO pattern is “0: [Conventional]”

Select and input a desired command position number in which a target position is registered, and then
input the start signal.
Execute home return. The actuator will stop at the home position, and the home return completion
(HEND) and position complete (PEND) will turn ON.
The completed position output (PM1 to PM8) will remain OFF.
If there is an unused position data number, we recommend that you set a dedicated position number
for home return by setting “0” as the target position.

z When the PIO pattern is “5: [4 points]”

Input the movement command to each position (ST0 to ST3).
Home return is executed first and the actuator stops at the home position. Then, the home return
completion signal (HEND) and position complete signal (PEND) will turn ON.
The complete signal for each corresponding position (PE0 to PE3) remains OFF.

z When the PIO pattern is other than “0: [Conventional]” or “5: [4 Points]”
Input the home return signal (HOME).
When home return is complete, the home return completion (HEND) and position complete (PEND) will
turn ON.
(Note) As in the conventional pattern, you can also execute home return by selecting and inputting a
desired command position number in which a target position is registered, and then inputting
the start signal.
However, use of the home return signal (HOME) is simpler and therefore recommended.

(Note) Difference in alarm reset method

• If the PIO pattern is “0: [Conventional],”actuate an emergency stop or cut off the motor drive power first,
and then input the start signal (CSTR) for at least 6 msec.
Thereafter, cancel the emergency stop or connect the motor drive power.
• If the PIO pattern is other than “0: [Conventional],” input the reset signal (RES) for at least 6 msec.

Reference: Processing on the PLC side

It is recommended that an interlock be provided in such a way that the PLC will detect a
loss of absolute data if the home return completion (HEND) remains OFF when the
power is input, and thereafter refuse all commands other than a command for home
return.

78
7.2.3 Operation Timings at PIO Pattern = “0: [Conventional]”
(Example) 100 mm is set as the target position under position No. 3, and home position
has not been established yet
[Operation with the standard controller]

Command position PC1

PC2

Start CSTR

Position complete PEND

Home return completion HEND

Completed position PM1

PM2

Actuator movement

Mechanical end Home position Stops after moving to

the 100-mm position.

[Operation with the absolute-specification controller]

Command position PC1

PC2

Start CSTR

Position complete PEND

Home return completion HEND

Actuator movement

Mechanical end Stops at the home position.

(Does not move to the 100-mm position.)

Note: With the absolute-specification controller, the actuator will not move to the target position if the
set position is “other than 0.”
Make sure the PLC can recognize that the actuator is stopped at the home position.

79
7.2.4 Operation Timings at PIO Pattern = “5: [4 Points]”
(Example) When “30 mm” is set as the target position in position No. 0 (Rear end), and the
home position is not yet established.

[Operation with the standard controller]

Rear end move ST0

Position complete REND

Home return completion HEND

Rear end complete PE0

Actuator movement

Mechanical end Home position Stops after moving to

the 30-mm position.

[Operation with the absolute-specification controller]

Rear end move ST0

Position complete REND

Home return completion HEND

Actuator movement

Mechanical end Stops at the home position.

(Does not move to the 30-mm position.)

Note: With the absolute-specification controller, the actuator will not move to the target position if the
set position is “other than 0.”
Make sure the PLC can recognize that the actuator is stopped at the home position.

80
7.2.5 Operation Timings at PIO Pattern ≠ “0: [Conventional]” or “5: [4 Points]”

Home return HOME

Position complete PEND

Moving MOVE

Home return completion HEND

Actuator movement

Mechanical end Stops at the home position.

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

81
7.3 Home Return and Movement after Start (PIO Pattern = “1: [Standard]”)
First, force the position complete signal to turn ON by referring to 7.1, “How to Start.”
If home return has not yet been executed immediately after the system start, issuing a start command by
specifying a position will cause the actuator to return to the home before moving to the specified position.
Example of use in operation) Home return is performed after the power ON, followed by positioning 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

RCP2 controller

Reference flow
PIO
Power ON
Signal name Category
[5] [2]
Start [1] Select/enter command position 1.
[1]
Command position 1
[2] Start input ON
Command position 2
Home return starts
Command position 4
Input
Command position 8 [3] Position complete output OFF
*Pause
[4] Moving output ON
P Reset

Servo ON [5] Start input OFF

[8]
L Completed position 1
Home return completes.
Completed position 2

C Completed position 4 [6] Home return completion output ON

Completed position 8
Movement to position 1 starts.
[7] [3]
Position complete Output
[6] Position complete output turns ON 0.1 mm
Home return completion [7] before position 1.
Zone
[8] Completed position 1 is output.
*Alarm
Ready [9] Moving output OFF
[9] [4]
Moving
Movement to position 1 completes.

82
 Command position Position 1

Start T1 Note

Position complete

Completed position Position 1

Home return
completion

Moving

Speed Positioning band

Actuator movement
Time

Mechanical end Home

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: 6 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 (position complete output has turned OFF) 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.

Start

Position complete

Moving 1 msec or less

Actuator
Movement is complete.

83
7.4 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.

RCP2 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
[7] Completed position 1
L [15] [7] Completed position 1 is output.
Completed position 2
[8] Moving output OFF
Completed position 4
C [9]
Completed position 8 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
Ready
[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.

84
 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

T1 T1 T1 T1
Start

Position complete

Moving Note Note Note

Completed position
Position 1 Position 2 Position 1
Speed

Actuator movement

T1: 6 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 (position complete output has turned OFF) 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.

Start

Position complete

Moving 1 msec or less

Actuator
Movement is complete.

85
7.5 Push & Hold Mode
First, cause the position complete signal to turn ON by referring to 7.1, “How to Start.”
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 stepper 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.
RCP2 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. Stepper motor current rises
to the current-limiting value.
[7]
L Completed position 1
[6] Position complete output ON
[15]
Completed position 2
[7] Completed position 1 is output.
C 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
Ready
[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.

86
 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

T1 T1 T1

Start

Position complete

Moving Note Note Note

Completed position
Position 1 Position 2 Position 1
Speed
Actuator movement

T1: 6 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.

7.5.1 Return Action after Push & Hold by Relative Coordinate Specification
It should be noted that in a return action by relative Speed
coordinate specification, the reference position is not the
current position at which the actuator is stopped after
completing the push & hold. Rather, it is the target
position specified in the position number with which the
push & hold was executed.
In the above example, the actuator will move to the 240- Return action
mm position (280 – 40) if a relative coordinate of -40 mm
is set in position No. 2. 240 mm 280 mm Push & hold completion 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 (position
complete output has turned OFF) 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

Speed Position 1 Position 2 Position 1

Actuator movement

If the actuator has missed the load, the position

complete output will not turn ON.

87
7.6 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.)
RCP2 controller
PIO Reference flow
[1] Select/enter command position 1.
Signal name Category
[11] [9] [5] [2]
[2] Start input ON
Start
[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 [6] Select/enter command position 2.

Servo ON Position complete output turns ON

[7]
L [8] 10 mm before position 1.
Completed position 1
[13] [8] Completed position 1 is output.
Completed position 2
C
Completed position 4 [9] Start input ON

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

[12] [10] [7] [3]
Position complete Output
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.
Ready
[14] [4] [13] Completed position 2 is output.
Moving

[14] Moving output OFF

Movement to position 2 completes.

88
 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 10 0
2 200 100 0.3 0 0.1 0
x
x
x

Command position Position 1 Position 2

T1 T1

Start Note Note

Position complete

Completed position Position 2

Position 1

Moving

Speed

Actuator movement

T1: 6 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 (position complete output has turned OFF) while the start signal remains ON.

89
7.7 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.

RCP2 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

Servo ON
[7] [4] Moving output ON
L Completed position 1

Completed position 2
[5] Start input OFF
C
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.

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

[8] Moving output OFF

Movement to position 1 completes.

90
 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

T1

Start

Position complete

Completed position Position 1

Moving

Speed

Positioning band
Actuator movement

Acceleration at maximum 0.1 G

motor torque

T1: 6 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 (position complete output has turned OFF) 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.

Start

Position complete

Moving 1 msec or less

Actuator
Movement is complete.

91
7.8 Pause
Example of use in operation) The actuator is paused during movement.
Method) Use the pause input.

RCP2 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
[5] Start input OFF
[11] Completed position 2
C
Completed position 4
Pause input OFF (Actuator
[6]
decelerates to a stop.)
Completed position 8
[10] [3] Position complete Output
[7] Moving output OFF
Home return completion

Zone [8] Pause input ON (Movement starts.)

*Alarm
[9] Moving output ON
Ready
[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.

92
 Command position

Start Note

Position complete

Completed position

Pause

Moving
4 msec or less

Speed

Actuator movement

Deceleration to a stop Start of remaining movement

T1: 6 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 (position complete output has turned OFF) 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.)
If parameter No. 25 (I/O pattern) is set to “0: [Conventional],” the reset input is not available.

Command position

Start

Position complete

Completed position

Pause
4 msec or more

Reset

Moving
Speed

Actuator movement

93
7.9 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:
Parameter No. 1 Zone boundary+ 120
Parameter No. 2 Zone boundary– 40
If parameter No. 25 is set to “3: [2 zone output signals],” two zone output signals are available. Set the
second zone value using parameter No. 23 (Zone 2+) and No. 24 (Zone 2–).
Note) The zone function is not available if parameter No. 25 (PIO pattern) is set to “2: [64-point
positioning]” or “4: [Teaching].”

RCP2 controller
PIO Reference flow
Signal name Category [1] Select/enter a desired command position.
[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
Servo ON
L
Completed position 1 Start input OFF
[5]

C [9] Completed position 2

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

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

Home return completion

[8] Position complete output ON
[7] [6]
Zone
[9] Completed position is output.
*Alarm

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

94
 Command position

T1
Start Note

Position complete

Completed position

Zone

Moving

Speed

Actuator movement

40 mm 120 mm

T1: 6 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 (position complete output has turned OFF) 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

120 40

Zone boundary+ Maximum stroke length Zone boundary+ 40

Zone boundary– 120 Zone boundary– 0

95
7.10 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.
RCP2 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

Servo ON [6] Position complete output ON

L [7]
Completed position 1 [7] Completed position 1 is output.
[15]
Completed position 2
C [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
Ready
[16] [11] [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.

96
 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

T1 T1

Start
Note 1
Position complete Note 2

Completed position
Position 1 Position 2 Position 2

Moving
Speed

Actuator movement
Time
30 40 50 60 70

Distance from home

T1: 6 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 (position complete output has turned OFF) 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.

Start

Position complete

Moving 1 msec or less

Actuator
Movement is complete.

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.

97
7.11 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.

98
 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:

RC model Speed type Lead [mm] Maximum error range [mm]

RCP2 -RPA 1 0.00125
RCP2 -SA5 Low speed 3 0.00375
-SA6 Medium speed 6 0.0075
-SS (R) High speed 12 0.015
RCP2 -SM Low speed 5 0.00625
-SMR Medium speed 10 0.0125
High speed 20 0.025
RCP2 -RSA Low speed 2.5 0.003125
-RXA Medium speed 5 0.00625
-RFA High speed 10 0.0125
RCP2 -RMA Low speed 4 0.005
-SA7 Medium speed 8 0.01
High speed 16 0.02

Example) If an incremental move is repeated 10 times on a RCP2-SM high-speed controller, a

maximum error of 0.025 x 10 = 0.25 [mm] may generate with respect to the final
position.

To eliminate these cumulative errors, an absolute command must be executed before the error
tolerance is exceeded.

(4) Ball screw accuracy

The accuracy of the ball screw used in the RCP2 conforms to C10 under the JIS standard.

99
7.12 Jogging/Teaching Using PIO
First, cause the position complete signal to turn ON by referring to 7.1, “How to Start.”
If parameter No. 25 (PIO pattern) is set to “4: [Teaching],” the actuator can be jogged using PIO. The
current actuator position can also be read into the controller’s position table using PIO.
When reading the current position into the position table, all data other than position (speed, acceleration,
etc.), if not already defined, will be automatically set to the default values in the applicable parameters.
Note) If a teaching pendant is connected (PORT is ON), the current position cannot be read into the
position table.
Example of use in operation) The actuator is caused to move using the +jog input or –jog input and the
current position is read into position No. 1.

RCP2 controller
PIO Reference flow

Signal name Category

*Pause input OFF
[4]
Command position 1 [1] Reset input OFF
Start input OFF
Command position 2

Command position 4

Command position 8 [2] Operation mode input ON

[2] Input
Operation mode

+Jog
[4] [1] [3] Current operation mode output ON
*Pause

P [7] [5] [1]

Current-position write
Move the actuator using +jog input or
Start
[4] –jog input.
Select/enter command position 1.
L Servo ON

[4] [1] –Jog

Reset
C
[5] Current-position write input ON
Completed position 1

Completed position 2

Completed position 4 [6] Write completion output ON

Completed position 8
[3]
Current operation mode [7] Current-position write input OFF
Output
Write completion
[6]
Position complete

Home return completion

*Alarm

Ready

Moving

100
 Jogging/teaching timing

Operation mode (MODE)

Current operation mode (MODES)

+Jog
(*Pause)

-Jog
(Reset)

Command position Position 1

Current-position write
(Start) (PWRT)
T1
Write completion
(Position complete) (WEND)

T1: 20 msec or more; time after the current-position write input is turned ON until writing of the current
position is started

When the operation mode (MODE) input is turned ON, the current operation mode (MODES) output will
turn ON to activate the teaching mode where jogging and teaching can be performed using PIO.
The controller will not switch to the teaching mode unless the operation mode (MODE) input is turned ON
while the pause input, reset input and start input are OFF.
To check if the controller is in the teaching mode, check if the current operation mode (MODES) output is
ON.
The actuator will stop if both the +jog input and –jog input are turned ON. Turn OFF both inputs, and then
resume jogging in one direction.
If the current-position write (PWRT) input has remained ON for 20 msec or longer, the current actuator
position will be written to the selected command position number.
When the writing is complete, the write completion (WEND) output will turn ON. To check if the writing has
completed, check if the write completion (WEND) output is ON.
Turning OFF the current-position write (PWRT) input will cause the write completion (WEND) output to
turn OFF.

Note: Be sure to enable the pause signal using parameter No. 15 (by setting the parameter to “0”)
(the pause signal is enabled at the factory). The system cannot switch to the teaching mode if
the pause signal is disabled (i.e., the above parameter is set to “1”).

If a signal to be written is input from the PLC while the position table screen is open on the PC or
teaching pendant, the position data display will not be refreshed. Perform one of the following operations
to check the retrieved position data:
PC --- Click the button.
Teaching pendant --- Turn on the PORT switch.

101
7.13 Operation in the “4 Points (Air Cylinder)” Mode
First, refer to 7.1, “How to Start,” to turn ON the position complete signal.
Example of operation) Turn on the power, and then cause the actuator to move back and forth between
the rear end (5 mm) and front end (390 mm) via intermediate point 1 (200 mm)
(based on the standard specification).

RCP2 controller
PIO Reference flow
Category [1] The rear end move input turns ON
Signal name
[1] [5] [14]
Rear end move Home return starts
[10] [13]
Front end move
[6] [9] [2]
Intermediate point 1 move Input The position complete output turns OFF

Intermediate point 2 move

[3] Home return completes
P *Pause

Reset The home return completion output turns ON

[4] [7]
L Rear end complete
[12] [15] The actuator starts moving to the rear end
Front end complete
[8] [11]
Intermediate point 1 complete
The actuator arrives at the rear end,
C [4] upon which the rear end complete
Intermediate point 2 complete Output output turns ON.
Zone
[2] [5] The rear end move input turns OFF
Position complete The intermediate point 1 move input
[3]
[6] turns ON
Home return completion
*Alarm The actuator starts moving to
[7] intermediate point 1
The rear end complete output turns OFF

The actuator arrives at intermediate point

[8] 1, upon which the intermediate point 1
complete output turns ON

[9] The intermediate point 1 move input turns

OFF
[10] The front end move input turns ON

The actuator starts moving to the front end

[11] The intermediate point 1 complete output
turns OFF

The actuator arrives at the front end, upon

[12] which the front end complete output turns
ON

[13] The front end move input turns OFF

[14] The rear end move input turns ON

The actuator starts moving to the rear end

[15] The front end complete output turns OFF

102
Rear end move

Intermediate point 1
move

Front end move

Position complete

Home return
completion

Rear end complete

Intermediate point 1
complete

Front end complete

Speed

Actuator movement
Mechanical end

Intermediate point 1
Home position

Front end
Rear end

Note: Movement commands are executed based on the rise edge, so input each signal continuously
for 6 msec or more.
If two or more movement commands are input simultaneously, they will be executed according
to the following priorities:
Priorities: [1] Rear end, [2] Front end, [3] Intermediate point 1, [4] Intermediate point 2
The sequence circuit on the PLC side must ensure only one command is input at a time.

103
V The movement command input operates in two modes.

You can select the operation condition of the movement command input (ST0 to ST3) in parameter No.
27.
The factory setting is “0: [Level mode].”

Description of the movement command input Setting

Level mode: 0
The actuator starts moving when the input signal turns ON. When the
signal turns OFF during the movement, the actuator will decelerate to a
stop and complete its operation.
Edge mode: 1
The actuator starts moving when the rise edge of the input signal is
detected. The actuator will not stop even when the signal turns OFF
during the movement, until the target position is reached.

[Level mode]

Movement command input

(ST0 to ST3)

Position complete
(PE0 to PE3)
Stopped
Actuator movement

Target position

(Note) Turn OFF the movement command input after confirming that the target position has been
reached.

[Edge mode]

Movement command input

(ST0 to ST3)

Position complete
(PE0 to PE3)

Actuator movement

Target position

104
V Handling of the pause (*STP) signal

This signal is a contact B signal, meaning that it must remain ON while the actuator is moving.
If the pause signal turns OFF while the actuator is moving, the actuator will decelerate to a stop.
The actuator will start moving when the signal turns ON again.
Use this signal as an interlock that actuates when an operator entry prohibition sensor or contact prevention
sensor is activated.

If the pause signal is not to be used, set parameter No. 15 (Pause input disable selection) to “1,” and the
actuator will move even when this signal is OFF.

(Note) When the “edge mode” is selected as the movement command type, you can change the target
position while the actuator is stopped with this signal turned OFF, as follows:
[1] Input a reset signal (RES) for 6 msec or more to cancel the remaining travel.
Next, turn ON the pause signal, and then input a movement command specifying the new target
position.
(Example) If the pause signal is turned OFF while the actuator is moving following the input of an
intermediate point 1 move command, the accelerator will decelerate to a stop.
→ Turn OFF the intermediate point 1 move signal, and then turn ON the reset signal for
6 msec or more.
→ Turn ON the pause signal again, and then input the front end move signal.

Intermediate point 1 move

Front end move

(ON for 6 msec or more)

Reset

Pause

Front end complete

Stopped
Actuator movement

The front end becomes the target position.

[2] After inputting a movement command specifying the new target position, turn ON the pause input.
(Example) If the pause signal is turned OFF while the actuator is moving following the input of an
intermediate point 1 move command, the accelerator will decelerate to a stop.
→ Turn OFF the intermediate point 1 move signal, and turn ON the front end move
signal.
→ When the pause signal is turned ON again, the controller will recognize the front end
as the new target position.

Intermediate point 1 move

Front end move

Pause

Front end complete

Stopped
Actuator movement

The front end becomes the target position.

105
8. Parameters
8.1 Parameter Classification
Parameters are classified into four types according to their content.
Category:
a: Parameter relating to the actuator stroke range
b: Parameter relating to the actuator operating characteristics
c: Parameter relating to the external interface
d: Servo gain adjustment

8.2 Parameter Table

No. Category Name Unit Default factory setting
1 a Zone boundary 1+ mm Effective actuator length
2 a Zone boundary 1– mm Effective actuator length
3 a Soft limit+ mm Effective actuator length
4 a Soft limit– mm Effective actuator length
Home return direction (In accordance with the specification at the time
5 a -
(0: [Reverse]/1: [Forward]) of order)
6 b Push & hold stop judgment period msec 255
Set individually in accordance with the actuator
7 d Servo gain number -
characteristics.
Set individually in accordance with the actuator
8 b Default speed mm/sec
characteristics.
Set individually in accordance with the actuator
9 b Default acceleration/deceleration G
characteristics.
10 b Default positioning band (in-position) mm 0.10
11 b Default acceleration only MAX flag - 0
Current-limiting value at standstill during Set individually in accordance with the actuator
12 b %
positioning characteristics.
Set individually in accordance with the actuator
13 b Current-limiting value during home return %
characteristics.
14 (Reserved for future expansion)
Pause input disable selection
15 c - 0
(0: [Enable]/1: [Disable])
16 c Serial communication speed bps 38400
17 c Minimum delay time for slave transmitter activation msec 5
18 (Reserved for future expansion)
19 (Reserved for future expansion)
20 (Reserved for future expansion)
Servo ON input disable selection
21 c - 1
(0: [Enable]/1: [Disable])
Set individually in accordance with the actuator
22 a Home return offset mm
characteristics.
23 a Zone boundary 2+ mm Effective actuator length
24 a Zone boundary 2– mm Effective actuator length
25 c PIO pattern selection - 0: [Conventional]
26 b PIO jog speed mm/sec 100
27 c Movement command type (0: [Level] / 1: [Edge]) - 0: [Level]

(Note) The numbers are displayed on the PC software screen but not on the teaching pendant. The
category codes are provided only for convenience and not displayed on either the PC software
screen or teaching pendant.

106
8.3 Parameter Settings

If a parameter has been changed, always restart the controller using a software reset command or by
reconnecting the power.

8.3.1 Parameters Relating to the Actuator Stroke Range

z Soft limit
Set the soft limit in the positive direction in parameter No. 3, and that in the negative direction in parameter
No. 4.
The factory setting for the soft limits conforms to the effective actuator length. Change the settings, as
necessary, to prevent crash with an obstacle or when the actuator must be stroked slightly beyond its
effective length.
A wrong soft limit setting will cause the actuator to crash into the mechanical end, so exercise due caution.
The minimum setting unit is “0.01 [mm].”
(Note) 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
Parameter No. 3 (positive side) 80.3
Parameter No. 4 (negative side) –0.3

Soft limits set in the controller

Approx.
0.3 mm
Approx.
0.3 mm
Effective range

0 8 0
Approx. 0.1 mm Approx. 0.1 mm

Allowable jogging/inching range after home return

z Zone boundary
Set the zone in which a zone output signal (ZONE1 or ZONE2) will turn ON.
(Note) ZONE2 is enabled only when “2 zone output signals” is selected as the PIO pattern.
The zone signal turns ON only when the current coordinate position is inside the negative (-) boundary
and positive (+) boundary settings.
The positive and negative boundaries for the ZONE1 signal are set in parameter No. 1 and No. 2,
respectively.
The positive and negative boundaries for the ZONE2 signal are set in parameter No. 23 and No. 24,
respectively.
The minimum setting unit is “0.01 [mm].”
Example) Use ZONE1 as an intermediate limit switch inside 100 and 200 mm, and use ZONE2 as a
simple ruler inside 270 and 275 mm, with an actuator having a 300-mm stroke
Parameter No. 1 (positive side) 200, parameter No. 2 (negative side) 100
Parameter No. 23 (positive side) 275, parameter No. 24 (negative side) 270

0
(Home) 100 200 270 275 300 mm

ZONE1 turns ON ZONE2 turns ON

107
z Home return direction
Unless specified by the user, the home return direction is set to the motor direction at the factory.
Should a need arise to change the home direction after the actuator has been assembled into your
system, reverse the setting in parameter No. 5 between “0” and “1.”
Also change the home return offset, if necessary.

Note: The home direction cannot be reversed for a rod-type actuator.

If the home direction is reversed, all position data that have been input will be cleared.

z Home return offset

The controller is shipped from the factory with an optimal value set in parameter No. 22, so the distance
from each mechanical end to the home becomes uniform.
The minimum setting unit is “0.01 [mm].”
The home return offset can be adjusted in the following conditions:
[1] Want to align the actuator home and the system’s mechanical home after the actuator has been
assembled into the system
[2] Want to set a new home after reversing the factory-set home direction
[3] Want to eliminate a slight deviation generated after replacing the actuator

Note: If the home return offset has been changed, the soft limit parameters must also be adjusted
accordingly.

8.3.2 Parameters Relating to the Actuator Operating Characteristics

z PIO jog speed
Define the speed at which the actuator will be jogged using PIO in the teaching mode.
The factory setting is “100 [mm/sec].”
Set an optimal value for the specific application.

z Default speed
The factory setting is the rated speed of the actuator.
When a target position is written to an unregistered position table or the current position is read in the
teaching mode, the setting in this parameter will be used as the speed data for the applicable position
number.
To reduce the default speed from the rated speed, change the setting in parameter No. 8.

z Default acceleration/deceleration
The factory setting is the rated acceleration/deceleration of the actuator.
When a target position is written to an unregistered position table or the current position is read in the
teaching mode, the setting in this parameter will be used as the acceleration/deceleration data for the
applicable position number.
To reduce the default acceleration/deceleration from the rated acceleration/deceleration, change the
setting in parameter No. 9.

Type Classification Initial value

Lead: 3 mm, 4 mm, 5 mm 0.2G
Slider
Lead: 6 mm or more 0.3G
RPA 0.05G
Rod
RXA/RSA/RMA 0.2G

108
z Default positioning band (in-position)
The factory setting is “0.10 [mm].”
When a target position is written to an unregistered position table or the current position is read in the
teaching mode, the setting in this parameter will be used as the positioning band data for the applicable
position number.
Increasing the default positioning band will allow the position complete signal to be output early. Change
the setting in parameter No. 10, as necessary.

z Default acceleration only MAX flag

To cause the actuator to decelerate gradually when stopping, a lower acceleration/deceleration should be
set. However, this will also reduce the acceleration.
This parameter allows for quick acceleration while reducing the deceleration.
The factory setting is “0: [Disable].”
When a target position is written to an unregistered position table or the current position is read in the
teaching mode, the setting in this parameter will be used as the acceleration only MAX data for the
applicable position number.
To enable the default value, change parameter No. 11 to “1: [Enable].”

z Push & hold stop judgment period

This parameter is used as a judgment condition when determining if the load was contacted and the push
& hold operation has completed.
The push & hold operation is judged complete if the current-limiting value set in the position table has
been maintained for the period set in parameter No. 6.
Set an optimal value by considering the shape and strength of the load, as well as the current-limiting
value.
The minimum setting unit is “1 [msec],” and the maximum judgment period is “255 [msec].” The factory
setting is “255 [msec].”
(Note) If the load has shifted and the current has changed during the push & hold judgment, the
judgment follows the timing chart shown below. This example assumes a judgment period of 255
msec.

Push current

Start position Target position Counting starts 20 msec

Counting continues until 200

Count is decremented to 180

75 msec
Count is incremented to 255

Judgment of push & hold completion

After reaching the push current, it is maintained for 200 msec. The current drops during the subsequent
20-msec period, and accordingly the count is decremented by 20. Therefore, when the operation is
resumed the count will start from 180. Since the count will reach 255 after 75 msec at the push current,
the controller will determine that the push & hold operation has completed.
In this example, the total judgment period is 295 msec.

109
z Current-limiting value at standstill during positioning
The factory setting conforms to the standard specification of the actuator.
Increasing this setting will increase the holding torque at standstill.
This setting need not be changed in normal conditions of use. However, to prevent hunting caused by
large external force applied while the actuator is at standstill, the value set in parameter No. 12 must be
increased.
(Do not increase the value beyond 70%.)

z Current-limiting value during home return

The factory setting conforms to the standard specification of the actuator.
Increasing this setting will increase the home return torque.
This setting need not be changed in normal conditions of use. However, if an increased slide resistance
causes the home return to complete before the correct position depending on the affixing method, load
condition or other factor when the actuator is used in a vertical application, the value set in parameter No.
13 must be increased.
(Do not increase the value beyond 75%.)

8.3.3 Parameters Relating to the External Interface

z PIO pattern selection
Select the PIO operation pattern in parameter No. 25.
This setting forms the basis of operation, so be sure to set this parameter at the beginning.
The factory setting is “0: [Conventional].”
Parameter No.
25 setting
Feature of PIO pattern
0 Conventional
This pattern is compatible with the pin assignments of the RCP controller.
1 Standard
All functions of the RCP controller are available, plus the home-return command
input, servo ON input, reset input, moving output and ready output.
2 64-point positioning
Compared with the standard pattern offering only 16 positioning points, this pattern
provides up to 64 positioning points.
However, the servo ON input, ready output and zone output have been removed.
3 2 zone output signals
Compared with the standard pattern offering only one zone output signal, this pattern
provides two zone output signals.
However, the moving output has been removed.
The boundaries for the second zone output signal are specified in parameter Nos. 23
and 24.
4 Teaching
This pattern allows for normal positioning operation, as well as jogging and writing of
current position to a specified position using I/Os.
Switching between the normal positioning mode and teaching mode is effected by the
MODE input signal.
The mode switching completion output has been added to indicate that the modes
have been switched.
However, the zone output has been removed.
(Note) Position data can be rewritten up to around 100,000 times.
5 4 points (air cylinder)
Use of the RCP2 as an air cylinder is assumed in this pattern.
The number of positioning points is limited to four, but a direct command input and a
position complete output are provided for each target position in line with the
conventional practice of air cylinder control.
This lets the user control the RCP2 just like an air cylinder.

110
z Movement command type
When the PIO pattern is set to “4 points,” define the operation condition of the movement command input
(ST0 to ST3) in parameter No. 27.
The factory setting is “0: [Level mode].”

Description of the movement command input Setting

Level mode: 0
The actuator starts moving when the input signal turns ON. When the
signal turns OFF during the movement, the actuator will decelerate to a
stop and complete its operation.
Edge mode: 1
The actuator starts moving when the rise edge of the input signal is
detected. The actuator will not stop even when the signal turns OFF
during the movement, until the target position is reached.

[Level mode]

Movement command input

(ST0 to ST3)

Position complete
(PE0 to PE3)
Stopped
Actuator movement

Target position

(Note) Turn OFF the movement command input after confirming that the target position has been
reached.

[Edge mode]

Movement command input

(ST0 to ST3)

Position complete
(PE0 to PE3)

Actuator movement

Target position

111
z Pause input disable selection
Parameter No. 15 defines whether the pause input signal is disabled or enabled.

Setting
Enable (use) the signal 0
Disable (do not use) the signal 1

The factory setting is “0: [Enable].”

z Servo ON input disable selection

Parameter No. 21 defines whether the servo ON input signal is disabled or enabled.

Setting
Enable (use) the signal 0
Disable (do not use) the signal 1

The factory setting is “1: [Disable].”

z Serial communication speed

Set the communication speed to be used when the control is performed via serial communication using
the PLC’s communication module.
Set an appropriate value in parameter No. 16 in accordance with the specification of the communication
module.
One of 9600, 19200, 38400 and 115200 bps can be selected as the communication speed.
The factory setting is “38400 [bps].”

z Minimum delay time for slave transmitter activation

This parameter defines the minimum delay until the controller’s transmitter will be activated after
completion of command reception, when serial communication is performed using the PLC’s
communication module.
The factory setting is “5 [msec],” but other necessary delay time must be set in parameter No. 17 if the
specification of the communication module exceeds 5 msec.

8.3.4 Servo Gain Adjustment

z Servo gain number
The factory setting is optimized in accordance with the standard specification of the actuator.
This setting need not be changed in normal conditions of use. However, an increased load may produce
noise during downward movements depending on the affixing method, load condition or other factor when
the actuator is used in a vertical application. In this case, decreasing the value set in parameter No. 7 will
be effective. However, do not decrease the value below “3 [msec]” to maintain an overall balance with the
actuator.

112
9. Controlling Multiple Controllers via Serial Communication
This section explains the connection method to be used when multiple controllers are controlled using the
PC or PLC’s communication module as the host.

9.1 Basic Specifications

Specification item Description
Maximum number of units that can be connected 16 units
Maximum cable length 100 m or less
Terminal resistor 220 Ω
Provide a communication path via bus connection and be sure to provide a terminal resistor at the end.

9.2 Connection Example

Teaching pendant
<RCA-T/TD>
Optional PC, etc.
PERSONAL
Cable length: 5
COMPUTER

PC software
<RCB-101-MW>
Optional
(Note) External equipment communication
RS232C cross cable cable <CB-RCA-SIO-***> cannot be
(Provided by the user) used for connection to a PC, PLC, etc.

SIO converter (with built-in terminal resistor)

<RCB-TU-SIO-A> Vertical type
<RCB-TU-SIO-B> Horizontal type
Components:
E-Con connector (AMP 4-1473562-4: housing color green)
E-Con connector (AMP 3-1473562-4: housing color orange)
Junction (AMP 5-1473574-4)
FG
0V Green Green Green
24V
Input power
supply
Terminal resistor
R = 220 Ω
Controller power
supply Controller link cable
<CB-RCB-CTL002>

ADRS switch: 0 ADRS switch: 1 ADRS switch: n-1

Controller 1 Controller 2 Controller n

Note: Do not connect the teaching pendant and PC at the same time.
If both are connected at the same time, a communication error (message level) will occur.

113
9.3 SIO Converter
This is a converter unit conforming to RS485/232C.
[2] Link-connection terminal block (TB1) [1] Power/emergency-stop terminal block (TB2)

FG
EMG2
EMG1
24V
0V
TB1
TB2

A B
[6] Monitor LEDs ON
LED1 LED2

RS232
PORT

[3] D-sub, 9-pin connector [5] PORT switch

[4] Mini DIN, 8-pin connector

[1] Power/emergency-stop terminal block (TB2)

EMG1, EMG2 Provide a contact output for the emergency-stop switch on the teaching pendant.
EMG1 and EMG2 connect to the emergency-stop switch on the teaching pendant
when the PORT switch is ON, or are shorted when the PORT switch is OFF.
These terminals comprise an interlock with a safety circuit provided by the user.
24V Positive side of the 24-V power supply (power supply for the teaching pendant and
conversion circuit)
0V Negative side of the 24-V power supply
FG FG of the 24-V power supply

(Note) 0V connects to pin 7 (GND) in the controller’s communication connector.

z Connection method
Use a connection cable satisfying the following specifications:

Item Specification
Applicable wire size Single wire: φ 0.8 to 1.2 mm / Stranded: AWG size 20 to 18 (end is soldered)
Stripped wire length 10 mm
Used for continuity check Insert a flathead screwdriver with a bit size of approx. 2.6 mm.

Connection cable

114
[2] Link-connection terminal block (TB1)
A connection port for linking the controller.
“A” on the left side connects to pin 1 (SGA) in the controller’s communication connector.
“B” on the right side connects to pin 2 (SGB) in the controller’s communication connector.
(Note) Be sure to use twisted pair wires for the above two connections (SGA/SGB).

[3] D-sub, 9-pin connector

A connection port with the host PC or PLC’s communication module.

[4] Mini DIN, 8-pin connector

A connection port with the teaching pendant.

[5] PORT switch

A switch for enabling/disabling the teaching pendant.
Set the switch to ON when a teaching pendant is used, or OFF when teaching pendant is not used.

[6] Monitor LEDs

LED1 --- Lit when the controller is transmitting
LED2 --- Lit when the RS232 is transmitting

115
9.4 Address Switch
Set an address (0 to 15) as a hexadecimal (0 to F) using the ADRS switch on the front panel of each
controller to define the slave number for the controller.
Assign “0” to the controller nearest the host, and then assign 1, 2, 3, …, E and F to the remaining
controllers in the direction of moving away from the host.
After all addresses have been set, reconnect the power.

Note: After the setting, be sure to confirm that the addresses are not duplicated.

Adjust the arrow to a desired position

using a flathead screwdriver.

9.5 Connection Cables

z Controller link cable
Model CB-RCB-CTL002

Controller end
200 mm
E-Con connector
6 8 3-1473562-4
3 5
(Housing color: Orange)
1 2 Mini DIN connector
Signal No. No. Signal
Yellow
SGA 1 1 SGA
Orange
SGB 2 2 SGB
+5V 3 3 GND
4 Blue 4
EMGA 5
+24V 6
GND 7
EMGB 8

(Reference) Connection diagram for RS232C cross cable

SIO converter end PC end

D-sub, 9-pin female connector D-sub, 9-pin female connector

Signal No. No. Signal
1 1
RD 2 2 RXD
SD 3 3 TXD
ER 4 4 DTR
SG 5 5 SG
DR 6 6 DSR
RS 7 7 RTS
CS 8 8 CTS
9 9

116
9.6 Detail Connection Diagram
Two-paired shielded cable
Recommended brand:
SIO converter Taiyo Electric Wire & Cable Four-way junction (AMP: 5-1473574-4)
HK-SB/20276XL

TB1
2PX22AWG 1[1] [2]
2
A 1 1

B 2 2
TB2 3 3
EMG2
4 4
EMG1
24V E-Con connector (AMP: 4-1473562-4)
0V Housing color: Green
FG
Controller link cable
CB-RCB-CTL002
Yellow Yellow
SGA 1 1 1 1 SGA
Orange Orange
SGB 2 2 2 2 SGB
Blue Blue
GND 7 3 3 7 GND

4 4 Controller 2
Controller 1
E-Con connector (AMP: 3-1473562-4)
Housing color: Orange

(Note) The user must provide the two-paired shielded cable.

If cables other than the recommended brands are connected to [1] and [2], use those with a cable-
sheath outer diameter of 1.35 to 1.60 mm.

Accessories (Optional):
[1] Controller link cable CB-RCB-CTL002 (connector on both ends), length 200 mm
[2] Four-way junction, made by AMP: 5-1473574-4
[3] E-Con connector, made by AMP: 4-1473562-4 (green)
[4] Terminal resistor 220 Ω (with E-Con connector)
Of the above, [2], [3] and [4] are provided for the same number as the controller link cables. Therefore, not
all units are needed when multiple axes are used.

117
10. Troubleshooting
10.1 Action to Be Taken upon Occurrence of Problem
Upon occurrence of a problem, take an appropriate action according to the procedure below in order to
ensure speedy recovery and prevent recurrence of the problem.
a) Check the status indicator lamps.
RDY (green) --- Power is supplied and the CPU is operating properly.
RUN (green) --- The servo is ON.
ALM (red) --- An alarm is present, or an emergency stop has been actuated or the motor drive
power is cut off.
b) Check for error in the host controller.
c) Check the voltage of the main 24-VDC power supply.
d) Check the voltage of the 24-VDC power supply for I/O signals.
e) Check for alarm.
Confirm the details of error on the PC or teaching pendant.
f) Check the cables for connection error, disconnection or pinching.
Before performing a continuity check, turn off the power (to prevent a runaway actuator) and
disconnect the cables (to prevent accidental power connection due to a sneak current path).
g) Check the I/O signals.
h) Check the noise elimination measures (grounding, installation of surge killer, etc.).
i) Review the events leading to the occurrence of problem, as well as the operating condition at the time
of occurrence.
j) Check the serial numbers of the controller and actuator.
k) Analyze the cause.
l) Take action.

Please check items a) through j) before contacting IAI.

(Reference) LED and output signal changes in each mode

Alarm is present Emergency-stop Motor drive power is

Servo OFF Servo ON (excluding message switch is pressed cut off (external cutoff
level alarms) (built-in cutoff relay) relay)
RDY (lamp) Lit Lit Lit Lit Lit
RUN (lamp) Unlit Lit Unlit Unlit Unlit
ALM (lamp) Unlit Unlit Lit Lit Lit
SRDY OFF ON OFF OFF OFF
∗ALM ON ON OFF ON ON
∗EMGS ON ON ON OFF

(Note) *ALM and *EMGS are based on the negative logic.

These signals remain ON in normal conditions of use while the power is supplied. They remain
OFF while the power is cut off.
They cannot be used as a contact-B interlock when the power is cut off.

118
10.2 Alarm Level Classification
Alarms are classified into three levels according to the symptoms they represent.

What happens when

Alarm level ALM lamp *ALM signal How to reset
alarm generates

Message Unlit Not output An error is displayed on the PC or teaching pendant.

Input the reset signal from the

The actuator decelerates
Operation PLC (Note 1).
Lit Output to a stop and then the
cancellation Reset by the PC/teaching
servo turns OFF.
pendant.
The actuator decelerates
Cold start Lit Output to a stop and then the Reconnect the power.
servo turns OFF.

(Note 1) Difference in alarm reset method from the PLC

• If the PIO pattern is “0: [Conventional],” actuate an emergency stop or cut off the motor drive
power first, and then input the start signal (CSTR) for at least 6 msec.
Thereafter, cancel the emergency stop or connect the motor drive power.
(This operation is effective on software version AD000007 or later supporting the absolute
specification.)
• If the PIO pattern is other than “0: [Conventional],” input the reset signal (RES) for at least
6 msec.

(Note 2) Reset each alarm after identifying and removing the cause. If the cause of the alarm cannot be
removed or when the alarm cannot be reset after removing the cause, please contact IAI.
If the same error occurs again after resetting the alarm, it means the cause of the alarm has
not been removed.

119
10.3 Alarm Description Output Using PIO
So that the PLC can recognize the nature of each alarm that has generated, alarm description is output
using the ports for completed position output signals (PM1 to PM8).
Configure the system in such a way that the PLC can determine whether the output is a completed
position number or alarm description based on the ON/OFF status of the alarm output signal (*ALM).

Bit assignment table for alarm description (z = OFF, { = ON)

∗ALM PM8 PM4 PM2 PM1 Description: Code number in ( )

{ x x x x Normal

z z { z { Nonvolatile memory data write error (F7)

Relating to position data/parameter
z z { { z • Data error at execution of bank 31 (B1)
• Data error at execution of bank 30 (B0)
z z { { { Excitation detection error (B8)

z { z z z Excessive actual speed (C0)

Relating to supply voltage
• Excessive motor supply voltage (C9)
z { z z {
• Excessive control supply voltage (CC)
• Drop in control supply voltage (CE)
z { z { z Overheating (CA)

z { z { z Deviation overflow (D8)

z { { z z Servo error (C1)

Relating to encoder disconnection
• Phase-A/B disconnection detection (E8)
• Phase-A disconnection detection (E9)
• Phase-B disconnection detection (EA)
z { { z {
Relating to absolute specification
• ABS error 1 (ED)
• ABS error 2 (EE)
• ABS error 3 (EF)
CPU error (FA)
z { { { z
FPGA error (FB)
z { { { { Corrupt nonvolatile memory data (F8)

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10.4 Alarm Description and Cause/Action
(1) Message level alarms

Code Error name Cause/Action

40 Emergency stop Cause: An emergency stop condition was detected.
(This is not an error.)
41 Motor voltage drop Cause: The “external cutoff relay” controller detected a motor drive-
power cutoff condition where the MPI and MPO terminals are
open.
(This is not an error.)
(Note) If this alarm generates when the MPI and MPO terminals are
closed, an internal failure of the controller is suspected.
5A Reception overrun This alarm indicates an error during PC or teaching pendant operation
or in the serial communication using the PLC’s communication module.
5B Reception framing error Cause: [1] Garbage data due to the effect of noise
[2] Duplicate slave numbers when multiple controllers are
5D Header error controlled by serial communication
[3] The teaching pendant and PC were connected at the same
5E Delimiter error time when the SIO converter was in use.
Action: [1] Adjust the wiring in a manner eliminating the effect of noise
7F BCC error and review the installation of equipment, etc.
[2] Change the slave numbers to avoid duplication.
[3] Connect only one at a given time.
61 FNCCHR, W address This alarm indicates an error in the serial communication using the
error PLC’s communication module.
62 Operand 1 error Cause: Undefined command or out-of-range data
Action: Review the transmitted data and correct the format.
63 Operand 2 error

64 Operand 3 error

65 EEPROM write timeout Cause: Writing of parameter or position data to the nonvolatile memory
area does not complete within 200 ms.
(This alarm will not generate in normal operation.)
Action: Do not write data from the PC or teaching pendant
simultaneously while a command is being issued from the PLC.
70 Movement command Cause: A movement command was issued while the servo was OFF.
during RUN-OFF Action: Issue a movement command after confirming that the servo is
ON (SRDY or PEND is ON).
73 Error reset during servo Cause: An alarm reset command was sent while the servo was ON
ON during an operation by serial communication.
(PIO commands are excluded.)
Action: Send an alarm reset command after confirming that the servo
is OFF.
75 Movement command Cause: The next movement command was issued during home return.
during home return Action: Issue the next movement command after confirming that the
home return has completed (HEND is ON).

121
 Code Error name Cause/Action
76 Soft reset during servo Cause: A soft reset command was sent while the servo was ON during
ON an operation by serial communication.
(PIO commands are excluded.)
Action: Send a soft reset command after confirming that the servo is
OFF.
77 Movement command Cause: A position movement command was entered from a PC or
during teaching teaching pendant while the teaching mode was selected.
(Only the JOG inputs are enabled in the teaching mode.)
Action: Switch to the normal mode before entering a position
movement command.
(Turn OFF the MODE input signal and check if MODES is
OFF.)
78 EEPROM written during Cause: Data was written from the PC or teaching pendant
teaching simultaneously while the MODE signal was being input from
the PLC (teaching mode).
Action: Do not edit data from the PC or teaching pendant
simultaneously while a command is being issued from the PLC.
7A ABS data backup battery Cause: The battery voltage was 4.4 V or below when the power was
voltage low warning input.
Action: Supply the power for at least 48 hours to charge the batteries.
(Moving the actuator will not affect the process of charging.)

(2) Operation-cancellation level alarms

Code Error name Cause/Action

B0 Bank 30 data error Cause: Data in the parameter area is outside the input range or invalid.
(This alarm will not generate in normal parameter input
operation, but may occur during serial communication using
the PLC’s communication module.)
Action: Transfer data after confirming that the parameter values are
valid.
B1 Bank 31 data error Cause: [1] A movement command was issued by selecting a number
to which no position data was registered.
[2] Position data value exceeds the soft limit setting.
[3] The timing of start signal is varied or too early.
Action: [1] Revise the sequence in such a way that unregistered
position numbers will not be selected.
[2] Change the position data to a value inside the soft limit
settings.
[3] The minimum timer setting may not be recognized
depending on the PLC. Pay attention to the timer setting.
BE Home return timeout Cause: Home return does not complete within the period set in the
applicable system parameter after the start of home return
operation.
(This alarm will not generate in normal operation.)
Action: The combination of controller and actuator may be wrong.
Please contact IAI.

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Code Error name Cause/Action
C0 Excessive actual speed Cause: This alarm indicates that the motor speed exceeded the
maximum speed set in the applicable system parameter.
This alarm will not generate in normal operation, but may
occur in the following conditions:
[1] Large actuator slide resistance in certain area, or
[2] Instantaneous increase in load due to application of
external force, which may cause the load to decrease and
actuator to move rapidly before a servo error is detected.
Action: Check for abnormality in the assembly condition of
mechanical parts.
If the actuator is suspected to be the cause, please contact
IAI.
C1 Servo error This alarm indicates that after receiving a movement command the
motor is unable to operate for two seconds or more before reaching
the target position.
Cause: [1] Loose or disconnected motor-relay cable connector
[2] Brake cannot be released on a controller equipped with
brake.
[3] Large load due to application of external force
[4] Large slide resistance of the actuator itself
Action: [1] Check the wiring condition of the motor relay cable.
[2] Check the wiring condition of the brake cable, and also
turn on/off the brake release switch to see if the brake
makes “click” sounds.
[3] Check for abnormality in the assembly condition of
mechanical parts.
[4] If the load is normal, cut off the power and move the
actuator by hand to check the slide resistance.
If the actuator is suspected to be the cause, please contact
IAI.
C9 Excessive motor supply This alarm indicates that the motor supply voltage is excessive (24V +
voltage 20%: 28.8V or more).
Cause: [1] High voltage of the 24-V input power supply
[2] Faulty part inside the controller
Action: Check the voltage of the input power supply.
If the voltage is normal, please contact IAI.
CA Overheating This alarm indicates that the temperature around the power transistor
in the controller is too high (95°C or higher).
Cause: [1] High temperature around the controller
[2] In the case of the dedicated controller for the high-thrust
type, the radiating fan may be faulty.
[3] Faulty part inside the controller
Action: [1] Lower the ambient temperature of the controller.
[2] Refer to 11, “Function Check and Replacement of the
Radiating Fan,” to check if the fan is faulty.
If the fan is faulty, replace the fan.
If taking the actions in [1] and [2] does not solve the
problem, please contact IAI.
CC Abnormal control supply This alarm indicates that the voltage of the 24-V input power supply is
voltage excessive (24V + 20%: 28.8V or more).
Cause: [1] High voltage of the 24-V input power supply
[2] Faulty part inside the controller
Action: Check the voltage of the input power supply.
If the voltage is normal, please contact IAI.

123
 Code Error name Cause/Action
CE Drop in control supply This alarm indicates that the voltage of the 24-V input power supply
voltage has dropped (24V – 20%: 19.2V or less).
Cause: [1] Low voltage of the 24-V input power supply
[2] Faulty part inside the controller
Action: Check the voltage of the input power supply.
If the voltage is normal, please contact IAI.
ED Absolute encoder error Cause: [1] The battery voltage was 4.4 V or below when the power
(1) was input.
[2] The current position has changed due to the effect of
vibration, etc., when the power was input.
Action: If code “7A” is displayed after the reset, the battery voltage is
low. Charge the batteries for at least 48 hours.
If “7A” is not displayed, turn off the power, and then turn it on
again by making sure the actuator does not vibrate.
Execute an absolute reset. (Note)
EE Absolute encoder error The absolute counter data in the FPGA is damaged.
(2) Cause: [1] The power was input for the first time after connecting the
batteries. (This message is always displayed at the initial
power on.)
[2] The parameter for home return direction or home return
offset was changed.
[3] The power supply was cut off for a prolonged period and
the battery voltage has dropped to a level at which the
absolute counter data can no longer be retained.
[4] The encoder cable or battery cable became open while
the power supply was cut off.
Action: If [4] is suspected, check the connectors and cables for loose
connections.
If the battery voltage is low, keep the power supplied for at
least 48 hours to charge the battery.
Execute an absolute reset. (Note)
EF Absolute encoder error Cause: The actuator was moved by hand and the motor speed
(3) exceeded 150 rpm while the power supply was cut off.
Action: Be careful not to move the actuator while the power is cut off.
Execute an absolute reset. (Note)
F7 EEPROM write error A current-position write signal (PWRT) was input in the teaching mode
when the controller was unable to receive the signal.
Cause: [1] The signal was input when home return was not yet
completed.
[2] The signal was input during jogging.
Action: [1] Input the signal after confirming that home return has
completed (HEND is ON).
[2] Input the signal after confirming that the JOG button is not
pressed or the actuator is stopped (MOVE is OFF).

(Note) How to execute an absolute reset when an ED, EE or EF error is present

[1] Reset the alarm (clear the error message) to turn the *ALM signal ON again.
[2] Perform home return.
These steps can be performed using the teaching pendant or PC or by issuing applicable
commands from the PLC. You can use any of these three methods, but be sure to perform the
above steps.
Refer to 7.1, “How to Start.”

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(3) Cold-start level alarms

Code Error name Cause/Action

B8 Pole sense error This controller will conduct excitation phase detection when the servo is
first turned ON after the power was input. This alarm indicates that the
specified encoder signal level cannot be detected after 100 ms of
excitation.
Cause: [1] Loose or disconnected motor-relay cable connector
[2] Brake cannot be released on a controller equipped with
brake.
[3] Large motor load due to application of external force
[4] Power was input when the actuator was contacting a
mechanical end.
[5] Large slide resistance of the actuator itself
Action: [1] Check the wiring condition of the motor relay cable.
[2] Check the wiring condition of the brake cable, and also turn
on/off the brake release switch to see if the brake makes
“click” sounds.
[3] Check for abnormality in the assembly condition of
mechanical parts.
[4] Move the actuator away from the mechanical end and then
reconnect the power.
[5] If the load is normal, cut off the power and move the
actuator by hand to check the slide resistance.
If the actuator is suspected to be the cause, please contact IAI.
D8 Deviation overflow The position deviation counter has overflowed.
Cause: [1] The speed dropped during movement due to the effect of
an external force, etc.
[2] The pole sense detection operation after power on is
unstable.
Action: [1] Check the load conditions—such as whether the load is
contacting a surrounding object or the brake is
disengaged—and then correct the abnormality, if any
[2] An overload condition is suspected, so review the load
weight. Reconnect the power and then execute home
return.
E8 Phase-A/B disconnection Encoder signals cannot be detected correctly.
detection Cause: [1] Loose or disconnected encoder-relay cable connector
E9 Phase-A disconnection [2] Loose or disconnected actuator-end connector of the
detection supplied cable
[3] The encoder relay cable connector was plugged in after
EA Phase-B disconnection
the battery connector (absolute specification).
detection
[4] If a high-thrust rod-type actuator is used together with an
actuator of other type, the encoder relay cables may be
connected wrongly.
Action: Check the connection condition of the encoder relay cable
and conduct continuity check. If the results are normal,
please contact IAI.
[3] is the cause, plug in the encoder relay cable connector,
and then plug in the battery connector.
If [4] is suspected, check the model numbers of the encoder
relay cables and connect the relay cables correctly.
Cable for high-thrust rod type: CB-RFA-PA***
Cable for other actuator type: CB-RCP2-PA***

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Code Error name Cause/Action
F8 Damaged nonvolatile Abnormal data was detected during the nonvolatile memory check after
memory starting.
Cause: [1] Faulty nonvolatile memory
[2] The memory has been rewritten more than 100,000 times.
(The nominal rewrite limit of the nonvolatile memory is
around 100,000 times.)
Action: If the alarm generates again after reconnecting the power,
please contact IAI.
FA CPU error The CPU is not operating properly.
Cause: [1] Faulty CPU
[2] Malfunction due to noise
Action: If the alarm generates again after reconnecting the power,
please contact IAI.
FB FPGA error The FPGA (gate array) of the absolute-specification controller is not
operating properly.
Cause: [1] Malfunction due to the effect of noise, etc.
[2] Faulty FPGA
[3] Defective board installation inside the controller
Action: Reconnect the power.
If the error persists, investigate possible noise sources.
If the cause cannot be specified, please contact IAI.

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10.5 Messages Displayed during Operation Using the Teaching Pendant or PC
Software
This section explains the warning messages that may be displayed during operation using the teaching
pendant or PC software.

Code Error name Cause/Action

112 Invalid data An inappropriate value was entered in a parameter.

(Example) 9601 was entered as the serial communication speed by mistake.
Enter an appropriate value again.
113 Value too small The entered value is smaller than the setting range.
114 Value too large The entered value is larger than the setting range.
Refer to the actuator specifications or parameter table and enter an appropriate
value again.
115 Home return non-completion The current position was written when home return was not yet completed.
Execute home return again.

116 Last position data Data already exists in the last position area of the position table when new data
is added.
Clear or delete the current last position data first.
117 No movement data Target position is not set under the selected position number.
Enter the target position first.

11E Paired data mismatch The values indicating the magnitude relationship of a pair of data are
inappropriate.
(Example) The same value was entered in both the parameters for + and – soft
limits.
Enter appropriate values again.
11F Absolute position too small The minimum movement toward the target position is determined by the lead
length of the drive system and resolution of the encoder.
This message indicates that the entered target value is smaller than the
minimum movement.
(Example) If the lead length is 20 mm, the encoder’s resolution is 800 pulses
and accordingly the minimum movement becomes 20 ÷ 800 = 0.025
mm/pulse.
In this case, this message will be displayed if 0.02 mm is entered as the target
position.
121 Push & hold search end The final position in push & hold operation exceeds the soft limit.
over This has no negative effect if the actuator contacts the load. If the actuator
misses the load, however, the soft limit will be reached and thus this message is
displayed as a warning.
Change either the target position or positioning band.
122 Multiple axes connected at Address was assigned when multiple axes were connected.
assignment Assign each address only when one axis is connected.

180 Address change OK These messages are displayed to confirm operation.

181 Controller initialization OK (They don’t indicate an operation error or other abnormality.)
182 Home change all clear
201 Emergency stop An emergency stop condition was detected. (This is not an error.)

20A Servo OFF during operation This message indicates that the servo ON signal (SON) was turned OFF by the
PLC while the actuator was moving, and that the servo turned OFF and the
movement was disabled as a result.

127
Code Error name Cause/Action

20C CSTR-ON during operation This message indicates that the start signal (CSTR) was turned ON by the PLC
while the actuator was moving, and that duplicate movement commands
occurred as a result.
20D STP-OFF during operation This message indicates that the pause signal (*STP) was turned OFF by the
PLC while the actuator was moving, and that the movement was disabled as a
result.
20E Soft limit over This message indicates that a soft limit was reached.

20F Push & hold missed-contact This message indicates that the actuator didn’t contact the load during push &
detection hold operation.
Check the load condition and review the target position/positioning band
settings.
210 HOME-ON during operation This message indicates that the home return signal (HOME) was turned ON by
the PLC while the actuator was moving, and that duplicate movement
commands occurred as a result.
211 JOG-ON during operation This message indicates that the jog signal (JOG) was turned ON by the PLC
while the actuator was moving, and that duplicate movement commands
occurred as a result.
301 Overrun error (M) These messages indicate an error in the serial communication with the
302 Framing error (M) controller.
304 SCIR-QUE OV (M) Cause: [1] Garbage data due to the effect of noise
305 SCIS-QUE OV (M) [2] Duplicate slave numbers when multiple controllers are controlled
306 R-BF OV by serial communication
308 Response timeout (M) Action: [1] Adjust the wiring in a manner eliminating the effect of noise and
30A Packet R-QUE OV review the installation of equipment, etc.
30B Packet S-QUE OV [2] Change the slave numbers to avoid duplication.
If the message is still displayed after taking the above actions, please contact
IAI.
307 Memory command refused This message indicates that the command was refused in the serial
communication with the controller.
309 Write address error This message indicates that an indeterminate WRITE address error occurred in
the serial communication with the controller.
These conditions do not occur in normal operation. Should they occur, record
the entire error list before cutting off the power for use in the cause
investigation.
Also contact IAI.
30C No connected axis This message indicates that no controller address is recognized.
Cause: [1] The controller is not operating properly.
[2] Only the supplied communication cable (SGA/SGB) is
disconnected.
[3] If a SIO converter is used, 24V is supplied to the converter but the
link cable is not connected.
[4] The ADRS switch settings are duplicated by mistake when
multiple controllers are linked.
Action: [1] Check if the RDY lamp on the controller is lit. If the lamp is not lit,
the controller is faulty.
[2] If a spare teaching pendant is available, replace the current
pendant with the spare unit, or with a PC, and see if the message
disappears.
[3] Supply power after connecting the link cable between the
converter and controller.
[4] Make sure the ADRS switch settings are not duplicated.
If the message is still displayed after taking the above actions, please contact
IAI.

128
10.6 Specific Problems
z I/O signals cannot be exchanged with the PLC.
Cause: [1] The 24-V I/O power supply is connected in reverse.
(This will not affect the input circuits, but the output circuits will be damaged.)
[2] If the problem is with an output circuit, a circuit component may have been damaged due
to a large load that caused the current flowing into the circuit to exceed the maximum
current.
[3] Contact failure in the connector or relay terminal block on the PLC end.
[4] Contact failure between the female pins in the flat cable connector and the male pins on
the controller due to expanded female pins.
Action: Check the connection condition of the power supply and connector, as well as the load on the
output side.
If the cause is identified as [1] or [2], the controller must be replaced. If there is a possibility of
[4], the flat cable must be replaced. Please contact IAI.

Note: When performing a continuity check of the flat cable, pay due attention not to expand the female
pins in the connector. It may cause contact failure and disable normal operation of the controller.

z The RDY lamp does not illuminate after the power is input.
Cause: [1] Reverse connection of the 24-V power supply
[2] Faulty controller
If the power supply is connected properly, probably the controller is faulty. Please contact IAI.
(Note) If the 24-V power supply is connected in reverse, the controller may not fail
immediately but its service life will likely be shortened.

z Only the RDY lamp illuminates when the servo ON signal is input after the power was input.
(The servo does not turn ON.)
Cause: [1] Contact failure of the flat cable
[2] Faulty controller
Check the servo ON signal (SON) on the I/O monitor screen of the PC or teaching pendant.
If the signal is input, probably the controller is faulty. Please contact IAI.

z Both the RDY lamp and ALM lamp illuminate when the power is input.
(An alarm is present, or an emergency stop has been actuated or the motor power is cut off.)
Check which of the alarm signal (*ALM) and emergency-stop signal (*EMGS) is output on the I/O
monitor screen of the PC or teaching pendant.
If the alarm signal is output, check the description of the error and remove the cause.
If the emergency-stop signal is output, check the following items:
[1] Is the emergency-stop switch on the operation panel pressed? Also confirm that the necessary
interlocks are released.
[2] Is the emergency-stop switch on the teaching pendant pressed?
[3] Is the PORT switch turned ON when neither teaching pendant nor PC is connected?
[4] If multiple controllers are connected, are the crossover wires connected correctly?
If the controller is of the external cutoff relay type, check the safety circuit.

129
z Home return ends in the middle in a vertical application.
Cause: [1] The load exceeds the rating.
[2] The ball screw is receiving torsional stress due to the affixing method of the actuator,
tightening of bolts only on one side, etc.
[3] The slide resistance of the actuator itself is large.
Action: [1] Increase the value set in parameter No. 13 (Current-limiting value during home return).
Increasing this value will cause the home return torque to increase, so do not increase the
parameter setting above 75%.
[2] Loosen the fixing bolts and check if the slider moves smoothly.
If the slider moves smoothly, review the affixing method and bolt tightening condition.
[3] If the slide resistance of the actuator itself is large, please contact IAI.

z Noise occurs during downward movements in a vertical application.

Cause: The load exceeds the rating.
Action: [1] Decrease the speed.
[2] Decrease the value set in the parameter No. 7 (Servo gain number). Do not decrease the
parameter setting below “3.”

z Vibration occurs when the actuator is stopped.

Cause: The slider is receiving an external force.
Action: If the external force cannot be removed, increase the value set in parameter No. 12 (Current-
limiting value at standstill during positioning).
Increasing this value will cause the holding torque at standstill to increase, so do not increase
the parameter setting above 70%.

z The actuator overshoots when decelerated to a stop.

Cause: The load inertia is high due to an inappropriate balance of load and deceleration.
Action: Decrease the acceleration/deceleration setting.

z The home and target positions sometimes shift.

Cause: [1] The encoder waveform is disturbed by the effect of noise.
[2] In the case of a rod-type actuator, the non-rotation accuracy increased due to application
of rotating moment to the rod.
Action: [1] Check if the grounding is implemented correctly. Also check for any equipment being a
potential noise source.
[2] The actuator may have to be replaced in some cases. Please contact IAI.

z The speed is slow during push & hold operation.

Cause: The set current-limiting value is low with respect to the load and slide resistance.
Action: Increase the current-limiting value for push & hold operation.

130
z The actuator moves only a half of, or twice as much as, the specified movement.
Cause: [1] The combination of controller and actuator is wrong.
The lead length of the ball screw varies depending on the actuator type, so a wrong
combination will cause the movement and speed to change.
[2] Factory setting error at IAI
Action: [1] If multiple actuators of different types must be used, confirm using the identification labels,
etc., that the correct actuator is connected to the controller.
[2] Please contact IAI.

z A servo error occurred while the actuator was moving (Robo Gripper).
Cause: The load was not positioned properly and contacted the finger attachment in the positioning
mode.
Action: Adjust the starting position of push action and the thickness of finger attachment (including
buffer material) by considering a possible offset of load position, so that the load can be
clamped properly in the push & hold mode.
Immediately after recovery from the error, the feed mechanism may still be locked. Be sure to
turn the open/close screw to loosen each finger attachment before resetting the alarm.]

Note: If the servo ON signal is disabled or the alarm is reset while the servo ON signal is still
ON, the servo will remain ON.
If the open/close screw is turned in this condition, the screw will return automatically and
the lock cannot be released. Therefore, reissuing a movement command will cause the
alarm to generate again.

Open/close screw
Turn the screw counterclockwise
using a flathead screwdriver.
OPEN

z Abnormal operation results when the servo is turned ON after the power ON.
Cause: Excitation phase detection was not performed correctly when the servo was turned ON,
because one of the following conditions existed when the power was input:
[1] The slider or rod was contacting the mechanical end.
[2] The load was being pushed by a strong external force.
Action: [1] Check if the slider or rod is contacting the mechanical end.
If the slider/rod is contacting the mechanical end, move it away from the mechanical end.
If the actuator is equipped with a brake, move the slider/rod after turning ON the brake
release switch to forcibly release the brake.
At this time, exercise caution not to allow the load to drop suddenly due to its own weight.
Your hand may be caught by the dropped load or the robot hand or load itself may be
damaged.
[2] Check if the load is contacting any surrounding part.
If the load is contacting any surrounding part, provide a clearance of 1 mm or more from the
applicable part.
If the checks in [1] and [2] did not find any problem, please contact IAI.

131
11. Function Check and Replacement of the Radiating Fan
The large-capacity type (RCP2-CF-***) has a built-in radiating fan.
To check the function of this fan and replace the fan when found faulty, follow the steps explained below.

1) Disconnect all connectors and cables from the controller, and then remove the fan unit.

Remove everything except for the MPI/MPO jumper wires.

2) Remove the resin case.

• The hooks on the mounting base plate are secured in the notches provided in the resin case. Pull the
case outward until the hooks are released, and then push up the mounting base plate.
Enlarged view of “A”

• Pull out the resin case.

132
3) Check if the fan is normal.
Check method:

[1] Connect the power cable to the 24V and N

terminals on the power terminal block.

[2] Turn on the power to see if the fan operates. If the

fan is normal, it will operate for approx. 3 seconds.
If the fan is faulty, it will not operate.

(Note) To prolong the life of the fan, the ambient temperature of the power transistor is detected using a
temperature sensor. The fan will start when the detected temperature rises to 60°C or above. If
the temperature drops to 45°C or below, the fan will stop.
For operation check, the fan is designed to operate for approx. 3 seconds when the power is
turned on.

4) If the fan is faulty, turn off the power and then replace the fan.
[1] Remove the fan.

Remove the pan-head screws

Removed fan
(M3 x 15, 2 pcs) affixing the fan.

Pull out the connector by hand.

[2] Affix the new fan using the pan-head screws, and then plug in the connector.
(Reference) Tightening torque of pan-head screw: 61.5 Nxcm (6.27 kgfxcm)

[3] To make sure, turn on the power to confirm that the fan will operate.

5) Turn off the power, and then disconnect the power cable.

6) Install the resin case.

Secure the hooks on the mounting base plate in the notches in the resin case.

7) Plug in all connectors and cables to their original positions.

133
 Appendix

* Appendix
Example of Basic RCP2 Positioning Sequence
Given below is an example of basic sequence for creating a positioning sequence using the RCP2.
indicates PIO signals of the RCP2 controller.
(Completed-position decoding circuit)
Position complete
PEND
Timer 1 Waiting for the completed position to be read
(Must be longer
Completed position codes
than the PLC’s
Timer 1 scan time.)
PM1 PM2 PM4 PM8
A Completed position 1
PM1 PM2 PM4 PM8 Timer 1
B Completed position 2
PM1 PM2 PM4 PM8 Timer 1
C Completed position 3
PM1 PM2 PM4 PM8 Timer 1
D Completed position 4
PM1 PM2 PM4 PM8 Timer 1
E Completed position 5

Create for the number of positions.

(Positioning circuit for position 1: When position 1 is set as the home)

Home return
request G
F Home-return start pulse
F Home return request
G Auxiliary home-return start pulse
G

Positioning
start request
to position 1 I
H Positioning start pulse to position 1 (home)
Positioning
start request
H to position 1
I Auxiliary positioning start pulse to position 1 (home)
I 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
F PEND HEND K
J Auxiliary positioning start for position 1 (home)
Current positioning
completed position
(E) H

J PEND L
K Start check for position 1 (home)
K
Auxiliary start
signal for next
positioning
K A (O)
L Completion of positioning to position 1 (home)
L
Check if positioning to the specified position has completed.

134
 Appendix

(Positioning circuit for position 2)

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

Current positioning
completed position

(A) M P
O Auxiliary positioning start for position 2
O

O PEND Q
P Start check for position 2
P

Auxiliary start
signal for next
P B positioning
Q Completion of positioning to position 2
Q 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
positioning to Set signal for
J O other position S other position
R Position 1 set

Auxiliary start
position for
positioning to Set signal for
other position other position
O J R
S Position 2 set

S 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.

135
 Appendix

R
PC1 Command position 1
Position 3
set signal

Position 5
set signal

S
PC2 Command position 2
Position 3
set signal

Position 6
set signal

PC4 Command position 4

PC8 Command position 8

(Start signal circuit)

J
Timer 2 Waiting for start
5 msec or more
O
(Must be longer
than the PLC’s
scan time.)
Start
command for
positioning to
other position

Timer 2

CSTR Start signal

136
 Appendix

Recording of Position-Data Table

Recorded date:
Speed Acceleration/ Positioning band Acceleration only
No. Position [mm] Push [%]
[mm/sec] deceleration [G] [mm] MAX
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

137
 Appendix

Valid only when [64-point positioning] is selected

Speed Acceleration/ Positioning band Acceleration only
No. Position [mm] Push [%]
[mm/sec] deceleration [G] [mm] MAX
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63

138
 Appendix

Recording of Parameters

Recorded date:
Category a: Parameter relating to the actuator stroke range
b: Parameter relating to the actuator operating characteristics
c: Parameter relating to the external interface
d: Servo gain adjustment

No. Category Name Unit Recorded data

1 a Zone boundary 1+ mm
2 a Zone boundary 1– mm
3 a Soft limit+ mm
4 a Soft limit– mm
Home return direction
5 a -
(0: [Reverse]/1: [Forward])
6 b Push & hold stop judgment period msec
7 d Servo gain number -
8 b Default speed mm/sec
9 b Default acceleration/deceleration G
10 b Default positioning band (in-position) mm
11 b Default acceleration only MAX flag -
12 b Current-limiting value at standstill during positioning %
13 b Current-limiting value during home return %
14 (Reserved for future extension)
Pause input disable selection
15 c -
(0: [Enable]/1: [Disable])
16 c Serial communication speed bps
17 c Minimum delay time for slave transmitter activation msec
18 (Reserved for future extension)
19 (Reserved for future extension)
20 (Reserved for future extension)
Servo ON input disable selection
21 c -
(0: [Enable]/1: [Disable])
22 a Home return offset mm
23 a Zone boundary 2+ mm
24 a Zone boundary 2– mm
25 c PIO pattern selection -
26 b PIO jog speed mm/sec
27 c Movement command type [0: Level / 1: Edge]

139
Catalog No.: RCP2C-MJ0136-8A-NOV2205-1

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