Master control unit, sysmac board, i/o link unit, transistor remote terminal, remote i/o terminal, relay-mounted remote terminal, connector terminal, sensor terminal, sensor amplifier terminal, analog input/output terminals, remote i/o module, position dr (82 pages)
Page 1
Cat. No. W138-E1-03 SYSMAC C500-NC222-E Two-axis Position Control Unit (NC221 Mode) OPERATION MANUAL...
Page 2
C500-NC222-E Two-axis Position Control Unit (NC221 Mode) Operation Manual Revised June 2003...
Page 4
OMRON. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is constantly striving to improve its high–quality products, the information contained in this manual is subject to change without notice.
About this Manual: The C500-NC222-E Position Control Unit in NC221 mode is a Special I/O Unit for SYSMAC C500, C1000H, and C2000H Programmable Controllers (PCs) that support WRIT (87) and READ (88). This Position Control Unit (PCU) in NC221 mode is designed to control positioning through voltage outputs to a motor driver according to PC programming and external control inputs.
Page 9
PRECAUTIONS This section provides general precautions for using the Programmable Controller (PC) and related devices. The information contained in this section is important for the safe and reliable application of the PC. You must read this section and understand the information contained before attempting to set up or operate a PC system. 1 Intended Audience .
It is extreme important that a PC and all PC Units be used for the specified purpose and under the specified conditions, especially in applications that can directly or indirectly affect human life. You must consult with your OMRON representative before applying a PC System to the abovementioned applications.
Application Precautions Caution The operating environment of the PC System can have a large effect on the lon- gevity and reliability of the system. Improper operating environments can lead to malfunction, failure, and other unforeseeable problems with the PC System. Be sure that the operating environment is within the specified conditions at installa- tion and remains within the specified conditions during the life of the system.
SECTION 1 Introduction The C500-NC222-E Position Control Unit (PCU) in NC221 mode is a Special I/O Unit that receives positioning commands from the Programmable Controller (PC) and outputs control voltages to two servomotor drivers. Since it outputs control volt- ages rather than pulses, it can be directly connected to any of a variety of servomotor drivers. You can use it with the C500, C1000H, or C2000H PC.
Applicable CPUs The C500-NC222-E Position Control Unit in NC221 mode can be used with a C500, C1000H, or C2000H PC. The C500-CPU11-EV1 CPU can be used with the C500, CVM1, CV500, CV1000, or CV2000 PC. Any C1000H and C2000H CPU may be used.
Page 14
Basic Operating Principles Section 1-2 The fundamental unit of positioning is the positioning action. A particular po- sitioning action moves the workpiece along the axis in a direction, at a speed, and to a position determined by the data which has been set specifically for the positioning action.
Section 1-4 System Configuration The following configuration illustrates example connections for a working sys- tem. Note The Position Control Unit cannot be used if mounted to a Slave Rack. Feedback inputs, control voltages C500-NC222-E Control inputs C500-TU002-E Teaching Box Emergency 24-VDC...
Semiclosed-Loop Systems The C500-NC222-E Position Control Unit is designed for use in a semi- closed-loop system. A semiclosed-loop system is similar to a closed-loop system, except that feedback is provided by a tachogenerator and a rotary...
Page 18
Control System Principles Section 1-6 cludes an error counter, a D/A converter, and a servomotor driver, detects machine movements by rotation of the motor in relation to the target, com- putes the error between the target value and actual movement, and zeroes the error through feedback.
Page 19
Control System Principles Section 1-6 The motor rotates at a speed corresponding to the speed voltage. The rotary encoder connected to the motor axis rotates in sync with the mo- tor, generates feedback pulses, and subtracts error counter contents. Desired position (pulses) Time...
Page 20
Control System Principles Section 1-6 In order to execute positioning by the semiclosed-loop method with ac- celeration and deceleration, target positions are set consecutively in the error counter for processing, thus enabling smooth acceleration and de- celeration. Desired position (pulses) Time Error counter...
The internal control cycle of the C500-NC222-E in NC221 mode is different from that of the C500-NC221-E. Accordingly, the output distribution cycle and external input read timing of the C500-NC222-E in NC221 mode are dif- ferent from those of the C500-NC221-E.
Page 22
Precautions When Using C500-NC222-E in NC221 Mode Section 1-7 There will be no timing errors if the C500-NC222-E in NC221 mode and the C500-NC221-E are in correct timing control operation, which however, does not mean that there is no difference in tact time between the C500-NC221-E and the C500-NC222-E in NC221 mode.
Page 23
Precautions When Using C500-NC222-E in NC221 Mode Section 1-7 Address Type Initial data and data attributes NC221 NC221 mode NC222 X-axis test X-axis test Position data: 500 Position data: 1,000 Position data: 1,000 data data 1 pulses; speed data: 1; M pulses;...
Page 24
Precautions When Using C500-NC222-E in NC221 Mode Section 1-7 Address Type Initial data and data attributes NC221 NC221 mode NC222 X-axis Origin parameter search direc- data tion Origin com- pensation Origin 5000 5000 5000 search maxi- mum speed Origin search...
Page 25
Precautions When Using C500-NC222-E in NC221 Mode Section 1-7 Address Type Initial data and data attributes NC221 NC221 mode NC222 Acceleration 463/863 Acceleration 00100040 00000700 00100040 and decel- and decel- eration pat- eration pat- tern tern 3 464/864 Acceleration 00100050...
Page 26
Precautions When Using C500-NC222-E in NC221 Mode Section 1-7 Address Type Initial data and data attributes NC221 NC221 mode NC222 Y-axis Unit setting parameter Pulse rate data Rotating direction Encoder type Gain In-position zone Backlash compensa- tion Stroke limit 999999...
Page 27
Precautions When Using C500-NC222-E in NC221 Mode Section 1-7 Address Type Initial data and data attributes NC221 NC221 mode NC222 Speed data Speed data 10000 10000 10000 Speed data 1000 1000 1000 Speed data 2000 2000 2000 Speed data 3000...
M/D Connector Section 2-1 M/D Connector The M/D (motor driver) connector is used for wiring servomotor driver I/O. Control voltage outputs and feedback pulse inputs go through here. The con- nector type and pin layouts are shown below. (Layout shown from wiring side) 2.6x8=20.8 2.6x6=15.6...
Page 30
M/D Connector Section 2-1 Pin Terminal Functions Pin No. Symbol Name Description DC GND 0-V terminal for pins 11 and 12 OUT-2X X-axis OUT2 output User defined output (for X axis) OUT-1X X-axis OUT1 output Phase B feedback input for X axis X-axis Phase B input X-axis Phase B input Phase B feedback input for X axis...
Page 31
M/D Connector Section 2-1 Input Circuits (Feedback Inputs for Phases A, B, and Z) 2 kW Phase A 1/6 W Phase A Photocoupler 330W 1/6 W (i) Phase A, phase A (X,Y axes) Typical Encoder A out 2 kW Phase B 1/6 W B out Phase B...
EXT-IN Connector The EXT-IN (external input) connector is used for wiring external inputs. Since the C500-NC222-E Position Control Unit allows dual axis control, the EXT-IN connector provides inputs for both X and Y axes for connecting in- puts from limit switches, from switches to stop the system, and from the me- chanical origin.
Faulty Wiring Diagnostic Function Section 2-3 Configuration of Input Circuit +24V 470 W Photocoupler 3.4 kW 1/3 W DC GND STP, ORG, EMG inputs (X,Y axes) External Interrupt Inputs External interrupt inputs are effective during operation, but their functions differ for 1) Positioning and searching for the origin and 2) JOG operations. During positioning or origin searches, setting of positions into the error count- er is stopped, and the count decreases naturally to cause a deceleration stop through workpiece momentum.
Page 34
Run-away motors are quite dangerous because they become ap- parent only after switching power on. The C500-NC222-E Position Control Unit counters this danger with the fol- lowing faulty wiring diagnostics in order to prevent run-away motors. • When the power is turned ON the error counter capacity has a limit so that a control voltage beyond ±0.3 V is not output.
Motor Driver Connection Examples In this example for 1-axis control, proximity and limit switch connections are wired to be current-activated. Set OUT1 and OUT2 as needed. External interrupt switch Emergency stop switch C500-NC222-E EXT-IN connector DC GND CCWL X CCW limit...
Motor Driver Connection Examples Section 2-4 In this example for 1-axis control, proximity switch connections are wired to be current-opening. Set OUT1 and OUT2 as needed. External interrupt switch Emergency stop switch C500-NC222-E EXT-IN connector DC GND CCW limit CCWL X STP X...
Wiring Precautions Section 2-5 Wiring Precautions Electronically controlled equipment may malfunction because of noise gener- ated by power supply lines or external loads. Such malfunctions are difficult to reproduce; hence, determining the cause often requires a great deal of time. The Position Control Unit is naturally susceptible to noise malfunction.
Before executing positioning actions, you must enter the necessary data into the EEPROM of the Position Control Unit. The C500-NC222-E Position Control Unit has a large data capacity. The EEPROM can store data for 300 positioning actions, 100 speeds, 19 parameters, 10 dwell times, and 10 acceleration and deceleration times per axis. You can set data most conveniently with the Teaching Box, but it is also possible to send data from the PC to the Position Control Unit.
Overview Section 3-1 Overview The Position Control Unit (PCU) outputs control voltage pulses to motor driv- ers. The basic control unit, therefore, is the pulse; control voltages differ by the number of pulses they contain. Pulse Rate Pulses are signals sent to motor drivers to command precise motor motion. In order to facilitate programming, the Teaching Box accepts input in units of pulses, millimeters (mm), or inches.
Data Allocations Section 3-2 Data Allocations Commands, parameters, speeds, positioning actions, dwell times, and accel- eration and deceleration times are stored at the following addresses. Posi- tioning actions include the position, speed, and other attributes. Parameters categorically establish limits and directions for positioning actions. Data PCU Address No.
Setting Parameters Section 3-3 Setting Parameters When writing data into the Position Control Unit for the first time, you must start with parameters. The word parameters, as used here, has a rather spe- cific meaning and refers to certain data settings (described below) which de- lineate particular aspects of operation.
Page 42
Setting Parameters Section 3-3 Rotation Direction (X axis: Relates to the position field sign bit. This parameter designates the control 402, Y axis: 802) voltage as positive or negative. The position field sign establishes the posi- tion field as positive or negative. 1 Word 1 Word Address...
Page 43
Setting Parameters Section 3-3 Encoder Type (X axis: 403, This parameter determines encoder characteristics. Y axis: 803) 1 Word 1 Word 1 Word Address 1 Multiplier 1 2 Multiplier 2 4 Multiplier 4 0 Positive logic 1 Negative logic Default: 01 (Positive logic, multiplier 1) Phase Z Logic Select positive logic (active high) or negative logic (active low) for the phase...
Page 44
Setting Parameters Section 3-3 Multiplier 2 and Multiplier 4 provide double and quadruple resolutions of the encoder for the motor, respectively. If an encoder with a resolution of 1,000 pulses/revolution is connected to a motor, the encoder controls minimum mo- tor rotation units in 1/2,000 revolution increments for Multiplier 2 and in 1/4,000 revolution increments for Multiplier 4.
Page 45
Setting Parameters Section 3-3 This parameter is used for reading the error counter value in the status area. Decide to read or not to read the error counter value when setting the gain set value. If the parameter is set to error counter value read, the error counter value will be output to words 17 to 20 (the data read area) of the status area in 8-digit BCD.
Page 46
Setting Parameters Section 3-3 The following diagram and timing chart show the relationships between the error counter count, the in-position zone, the In-position Flag, and other posi- tioning flags. As shown below, positioning is consider complete when the count in the error counter is less than or equal to the value set for the in-posi- tion zone.
Page 47
Setting Parameters Section 3-3 Stroke Limit (+) (X axis: Designates the limit in pulses for positive (+ area) positioning actions. A posi- 407, Y axis: 807) tioning action is positive or negative depending on the setting of the sign bit in the Attribute 1 field.
Page 48
Setting Parameters Section 3-3 Set the acceleration zone in order to check the amount of movement from the positioning starting point. The Acceleration Zone flag remains ON while the positioning action executes the number of pulses set for the acceleration zone.
Page 49
Setting Parameters Section 3-3 In the figure below for example, the parameter is set to shift positioning by 100 pulses. If the HSFT is enabled for positioning from P0 to P1 and to P2 (solid line), then positioning goes to (P1 + 100) and to (P2 + 100) (broken line).
Page 50
Setting Parameters Section 3-3 Origin Compensation Corrects the mechanical origin detected via the phase Z origin search. There (X axis: 414, Y axis: 814) may be times when the mechanical origin which is detected may not be suffi- ciently precise. In such cases, you can use this parameter to add a desig- nated number of pulses to the mechanical origin.
Page 51
Setting Parameters Section 3-3 Origin Search Acceleration Sets the acceleration and deceleration times for origin search. and Deceleration (X axis: 416, Y axis 816) 1 Word 1 Word Origin search Address acceleration and deceleration Range: 0 to 9 (Default: 5) The times available are stored in addresses 460-469 for the X axis and 860-869 for the Y axis.
Page 52
Setting Parameters Section 3-3 When the external interrupt input turns ON, the Deceleration Stop value is compared to the count in the error counter. If the count in the error counter is greater than the Deceleration Stop value, the Deceleration Stop value is not used and the system will stop after the positioning system has moved by the pulse count already in the error counter.
Setting Positioning Actions Section 3-4 External Output Control This parameter is used to set the error counter capacity and external output (X axis: 420, Y axis: 820) control. When the error counter overflows, external output 1 (OUT1) will be left as it is or turned OFF by setting external output 1 value to 1 or 0.
Page 54
Setting Positioning Actions Section 3-4 Position Field Positions for positioning actions are set using eight digits and may be be- tween –99,999,999 and +99,999,999 pulses. Out of the eight digits, the left- most four digits are held in one word and the rightmost eight digits are held in another word.
Page 55
Setting Positioning Actions Section 3-4 Attribute 1 Field You use this field to designate the interpolation code, position type (INC/ ABS), and position field sign (+/–). Attribute 1 field Positive field sign Positive Negative Positive type ABSolute INCremental Interpolation code 07 06 Name No interpolation...
Page 56
Setting Positioning Actions Section 3-4 Completion Codes The completion code determines whether a certain positioning action is part of a series or whether it terminates a series. Setting bit 00 to 0 designates a positioning action as terminating as shown below. Speed Time Í...
Page 57
Setting Positioning Actions Section 3-4 Circular Arc Interpolation This bit establishes the direction of interpolation when the circular arc center Direction and circular arc end point are defined. Interpolation end point CW circular arc interpolation CCW circular arc interpolation (clear bit 01 to1) Circular (set bit 01 to1) arc center...
Page 58
Setting Positioning Actions Section 3-4 If the positioning action at address 103 was to an absolute position rather than an incremental one, the following action would result. As you can see, enabling/disabling various positioning actions can be used to achieve a wide range of positioning without requiring changes in the ladder program.
Setting Acceleration and Deceleration Times Section 3-6 Setting Dwell Times In servomotor positioning, hunting can occur near the positioning destination because of gain. Sudden deceleration and high-speed movement over a short distance aggravate the tendency to hunt. To minimize the effects of hunting, positioning completed signals can be held for a certain duration or dwell time before they are set.
Setting Speeds Section 3-7 Acceleration time to operating speed = Acceleration time x (Target speed)/(Maximum speed) Deceleration time to operating speed = Deceleration time x (Target speed)/(Maximum speed) Maximum speed (411, 811) Operating speed (900-999) Acceleration time Deceleration time (460-469, 860-869) (460-469, 860-869) Acceleration and deceleration times are effective for the following operations only: Positioning actions;...
Initial Data Section 3-8 Initial Data The following tables list the default data loaded originally in the EEPROM at the factory. The operation of each of these is described in Section 3 Data Configuration. This data will be automatically loaded to RAM whenever pow- er is turned on.
Page 62
Initial Data Section 3-8 X-Axis Parameters Address Description Setting Attributes Unit Pulse Pulse rate 1 unit/pulse Rotation direction Positive voltage output with incremental positioning actions Encoder type Single multiplier, positive logic µ 2,000 V/pulse Gain pulses In-position zone None Backlash compensation pulses Stroke limit (+)
Page 63
Initial Data Section 3-8 Dwell Times (X and Y Axes) Address Description Setting Attributes 450/850 Dwell time #0 451/851 Dwell time #1 452/852 Dwell time #2 453/853 Dwell time #3 454/854 Dwell time #4 455/855 Dwell time #5 456/856 Dwell time #6 457/857 Dwell time #7 458/858...
Page 64
Initial Data Section 3-8 Y-Axis Positioning Actions Address Description Setting Attributes Y-axis test data (1) Position = 500 pulses, Dwell time = 500 ms speed = 1 kpps, M code = 06 Incremental, terminating, acceleration = 200 ms deceleration = 200 ms Y-axis test data (2) Position = 0 pulses, Dwell time = 0 ms...
Page 65
Initial Data Section 3-8 Y-Axis Parameters Address Description Setting Attributes Unit Pulse Pulse rate 1 unit/pulse Rotation direction Positive voltage output with incremental positioning actions Encoder type Single multiplier, positive logic µ Gain 2,000 V/pulse In-position zone 10 pulses Backlash compensation None Stroke limit (+) 999,999...
Compatible Models and Words Section 4-1 Compatible Models and Words Both data and commands can be transferred between the Position Control Unit (PCU) and Programmable Controller (PC) through the use of Intelligent I/O Read and Write instructions executed by the PC. Compatible Models The Intelligent I/O Read instruction READ(88) and Intelligent I/O Write in- struction WRIT(87) control PCU-PC communication.
PC Programs Section 4-2 PC Programs The PC program maintains two data flow directions. • PC to Position Control Unit (PCU) command and parameter transmission uses the Intelligent I/O Write instruction WRIT(87). Commands and param- eters are differentiated by address inside the PCU. •...
PC Programs Section 4-2 4-2-1 Basic Command Transmission Program (PC to Position Control Unit) WRIT(87) : Start input (differentiated input) : Status-holding work bit : Transmission completed work bit : Command Ready (bit 15 of first word ON when READ (85) is executed) : Differentiation no.
Page 71
PC Programs Section 4-2 Status Reception Problems The RAM in the PCU that contains status data is accessed both by the PCU to write the status and by the PC to read status (READ(88)). Both of these operation cannot take place at the same time. NC222-E READ(88) sent É...
PC Programs Section 4-2 Note READ(88) can be executed for the NC222 PCU only once each time the sta- tus is updated in the PCU (i.e., each time PCU internal status is written to the shared RAM). If the scan time of the CPU Unit is shorter than the status up- date time of the PCU (approx.
Page 73
PC Programs Section 4-2 Up to 127 words can be transferred each time WRIT(87) is executed. When it is necessary to transfer more words, the Equals Flag should be used to acti- vate further transmissions with WRIT(87), as shown below. When data is transferred into the NC222-E, data is automatically stored in RAM according to the addresses given.
Page 74
PC Programs Section 4-2 Program Bit to initiate data transfer DIFU(13) 5000 5000 5002 WRIT(87) #0027 5001 DM1000 When NC222-E is allocated IR 000 and IR 001 5001 5002 25506 5002 5004 WRIT(87) 5003 This section can be used for a second transfer when more than 127 words are required.
SECTION 5 Operating Status This section describes the status information available from the PCU. This information is read into the PC by executing the Intelligent I/O Read instruction, READ(88). Also explained in this section is the relationship between certain PCU commands and the status information.
Flag Transitions and Types Section 5-1 Flag Transitions and Types Relationship between Flags Flags and other status information will change as commands are executed. and Commands These changes are illustrated in the following illustration. When the com- mands along the arrow are executed, the flags given at the ends of the ar- rows turn ON.
Flag Transitions and Types Section 5-1 Types of Flags The Intelligent I/O Read instruction READ(88) is used to read blocks of flags and status data into a memory area in the PC. Their contents are as follows: System status flags Error codes System error status flags Error codes...
Status Word Allocations Section 5-2 Status Word Allocations The PC uses the Intelligent I/O Read instruction READ(88) to read status from the Position Control Unit. Refer to the end of 4-2 PC Programs for the READ(88) format. Data word allocations are summarized as follows: Com- Teach- Teach-...
Status Word Allocations Section 5-2 Parame- Origin Parame- Posi- Home Override Dwelling Position- Origin Inching Jogging Position- Stop Pause Emer- Current ters En- ters tioning Shift ing Com- search gency Position abled Cleared Data pleted Stop Sign Cleared Status flags (1) Accel- Constant Deceler-...
Status Word Details Section 5-3 Status Word Details 5-3-1 System Flags Word D + 0 Function Content Initially On error – Unused – – – – Data read Indicates that data Turns ON from OFF or OFF from ON completion has been read in the whenever data is read in the data read change...
Status Word Details Section 5-3 5-3-2 Error Code and System Error Flags Refer to Appendix D for error codes. Word D + 1 system Function Content Initially error Error Code Code in BCD (10 dig- When either a system er- If system error or Corre- it) indicating cause of...
Status Word Details Section 5-3 5-3-3 Error Op Codes Word D + 2 Function Content Initially On error Displays number of oper- ands in BCD of preced- ing Op code. Displays error-causing Op code rightmost digit Error Op When a When a proper in BCD.
Page 83
Status Word Details Section 5-3 system Function Content Initially error Inching Indicates inching. When PLS is received. When inching is completed, or a system error occurs. Origin Indicates origin When ORG is received. When origin search or STP is Search search completed, or when a system error occurs.
Page 84
Status Word Details Section 5-3 system Function Content Initially error External Indicates external When external interrupt When external interrupt input 0 or 1 Interrupt interrupt status. input is ON. is OFF. change CCWLS Indicates CCW limit When CCWLS input is When CCWLS input is OFF 0 or 1 Input...
Status Word Details Section 5-3 5-3-6 Current Position X-Axis: Word D + 5 Y-Axis: Word D + 12 Leftmost Digits system Function Content Updated Cleared Initially error Current Designates current When the origin (either When system error occurs. position position in BCD (10 by ORG or CCHG) is (leftmost 4 digit)
Page 86
Status Word Details Section 5-3 5-3-7 M Code X-Axis: Word D + 7 Y-Axis: Word D + 14 system Function Content Updated Cleared Initially error M code Designates M code When execution of a When execution of a posi- in BCD (10 digit ) positioning action with a tioning action without an M...
Flag Changes Section 5-4 5-3-9 Current Speed Address and Override Coefficient X-Axis: Word D + 9 Y-Axis: Word D + 16 system Function Content Updated Cleared Initially error –1 Override Designates 10 digit When OVR is received. – coefficient of override change coefficient in BCD.
Flag Changes Section 5-4 Flag Changes during Origin During origin search, status flags change in the following manner. Flags are Search set during the shaded area. Speed Origin Input Time Origin Stop Positioning Positioning Completed Origin Search CW/CCW Movement Origin Input Origin Origin Set Flag Changes during JOG...
Flag Changes Section 5-4 Flag Changes for Pauses Flags change in the following manner when HLD (Pause) and REL (Pause Release) are executed: Speed Time Stop Positioning Positioning Completed Pause M Code Accelerating Constant Speed Decelerating CW and CCW Movement In Position...
Page 90
SECTION 6 Commands This section describes the commands that are available to control PCU operation from the PC. Command Format ............Command Descriptions .
Command Format Section 6-1 Command Format There are three types of commands used. First, four system commands sup- port other command processing. Second, the servo control commands oper- ate the motors. Third, data processing commands handle data stored in the Position Control Unit.
Command Format Section 6-1 Command OP Code Allocations and Abbreviations ––– Rightmost digit Type Leftmost digits System commands ERST – – – – – – Com- Error re- Exter- No op- mand nal out- eration put con- trol XSRT XSTP XJDG XPLS XORG...
Command Descriptions Section 6-2 Command Descriptions 6-2-1 System Commands The following commands are used with WRITE(87) from the PC. Name Format Function Format explanation Command end (END) Indicates the end of OP code a command train. No operation (NOP) Does not do any- a..
Command Descriptions Section 6-2 6-2-2 Servo Control Commands The following commands are used with WRITE(87) for operations between the PC and PCU. Name Format Function Description Examples Start OP code Positioning A..Axis designation is executed 1: X axis XSRT according to 2: Y axis YSRT a position-...
Command Descriptions Section 6-2 Name Format Function Description Examples Pause OP code Pauses A..Axis designation positioning 1: X axis XHLD 2: Y axis Executing a pause YHLD 3: Both axes on the X axis. IHLD Pause release OP code Releases pause A..Axis designation on positioning 1: X axis...
Command Descriptions Section 6-2 6-2-3 Data Processing Commands The following commands are used with WRITE(87) for operations within the PCU. Name Format Function Description Examples All clear OP code Clears all data a..Speed data designated by 0: Does not clear ACLR the operand.
Page 97
Command Descriptions Section 6-2 Name Format Function Description Examples Transfer data OP code Transfers data a..Source address within internal b..Destination address RAM. Transferring contents of X-axis positioning action address 100 to address 101. Block transfer OP code Transfers multi- a..Source start address ple data words BMOV b..Source end address...
Command Processing Section 6-3 Command Processing The various commands have the following processing conditions. Command Processing condition Other conditions When Command Ready flag is ON. The command is ignored. NOP, OUT XOVR, YOVR, KIOVR XEMG, YEMG, IEMG ERST XHLD, YHLD, IHLD While Position Control Unit is operating.
Page 100
Interpolation Section 6-4 Position Positioning action X-axis Y-axis During Remarks data data interpolation Address X=123 X-axis and Y-axis addresses Y= 523 automatically correspond through their last two digits. Position X= P Positive Y= P Speed 100 <–> 500 ad (x) ad (y) ad (x) 101 <–>...
Interpolation Section 6-4 Circular Arc Interpolation Incremental Positions When using incremental positions for circular arc interpolation, the incre- ments for the intermediate or center point are measured from the starting point and the increments for the end point are measured from the intermedi- ate or center point.
Page 102
Interpolation Section 6-4 ISRT with Address 124 In this case the positioning action of address 124 is processed normally since Disabled it is an end point; furthermore, address 123 remains enabled as an intermedi- ate point. The entire operation proceeds normally. Starting point ISRT with Improper In this case a circular arc cannot be created with the designated positions,...
Page 103
Interpolation Section 6-4 Interpolation Speeds The speed set for the X axis will be used for linear and circular interpolation. For circular arc interpolation, this speed will be the speed along the tangent to the arc, as shown below. θ For linear interpolation, the speeds along the X and Y axes can be figured as follows: θ...
Relation between SRT and Positioning Actions Section 6-5 Relation between SRT and Positioning Actions The following table shows the positioning action fields pertinent to execution of XSRT, YSRT, and ISRT which initiate X-axis positioning, Y-axis positioning, and interpolated (both X and Y axes) positioning, respectively. If any perti- nent fields have erroneous data, then a command error occurs.
SECTION 7 Establishing the Origin The section describes how to establish the origin, either by defining the current position as the origin or by using origin and limit inputs to establish the mechanical origin. CCHG ..............Origin Search (XORG, YORG, IORG) .
Origin Search (XORG, YORG, IORG) Section 7-2 CCHG Before positioning, it is necessary to establish the origin as a reference point, by means of either CCHG (changing current position) or ORG (origin search). Use CCHG if it is difficult to establish the origin inputs mechanically or if you constantly need to re-establish the origin.
Origin Search (XORG, YORG, IORG) Section 7-2 The origin is established at the first phase Z pulse after the leading and trailing edges of the origin input. Speed Search direction Low origin search speed Time Starting position Origin input CCWLS CWLS Phase Z Search Starting between CCW Limit Input and Origin Input...
Origin Compensation Section 7-3 The origin is established at the first phase Z pulse after the trailing edge of the origin input. Search direction Pulses in Origin search high speed error Speed counter at CWLS Origin search low speed Time Start position Origin input CCWLS...
SECTION 8 Programming Examples This section provides example PC programs along with the commands and sample data used to achieve various types of positioning actions. Data Word Allocations ........... . . Data Transmission Program .
Data Word Allocations Section 8-1 Data Word Allocations The lowercase letters j, k, l, m, and n designate the IR and DM area words for the programming examples in this section. The Position Control Unit is mounted on word n for output and word n+1 for input. The value n depends on the mounting position of the Position Control Unit.
Page 111
Data Word Allocations Section 8-1 Remark DM No. m+31 m+32 Positioning Actions in DM Area Remarks DM No. X-axis address 100, point A X-axis address 102, origin (straight-line interpolation end point ) end point ) k+10 X-axis address 103,Point C (circular arc center) k+11 k+12 k+13...
Page 112
Data Word Allocations Section 8-1 Remarks DM No. k+33 k+34 k+35 X-axis address 108, origin k+36 k+37 k+38 k+39 Remark -b 8 DM No. k+50 k+51 k+52 Y-axis address 500, point B k+53 k+54 k+55 k+56 Y-axis address 501, point C k+57 k+58 k+59...
Data Transmission Program Section 8-2 Remark -b 8 DM No. k+78 k+79 k+80 Y-axis address 507, point A k+81 k+82 k+83 k+84 Y-axis address 508, origin k+85 k+86 k+87 AR Area Reference 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Subsection introduced ∅...
Page 114
Data Transmission Program Section 8-2 tioning action. For sequential transfers, the rightmost BCD digit in the ad- dress field of the first positioning action can be changed from 4, which states that four additional words follow the address as a positioning action, to 9. In this case you can set the total number of addresses involved in sequential transfer in the word that follows.
Page 115
Data Transmission Program Section 8-2 Transfer Program (1) Transfers the 8 positioning actions for the X axis. Because address 101 is empty and has no data, the group of 8 addresses is considered non-sequen- tial. j + 6 (02) l (15) j + 6 (00) WRIT(87) #0040...
Basic Program Examples Section 8-3 Basic Program Examples 8-3-1 Positioning to a Single Point (X Axis) The following program positions to point A [10,000, 0 (pulses)] from the origin [0,0 (pulses)] at 2 kpps. At point A, bit J(15) turns ON to indicate completed positioning.
Basic Program Examples Section 8-3 Ladder Diagram j+1(00) j+(15) DIFU(13) j+1(01) Start input Point A j+1(01) j+3(03) l(15) WRIT(87) j+1(02) Command #0002 Positioning to point C Ready via point B DM m+16 25506 (03) ( = ) (02) l+3(08) CMP(20) Positioning Point A Completed...
Basic Program Examples Section 8-3 8-3-3 Straight-Line Interpolation to a Single Point (X/Y Axis) The following program positions to point C [10,000, 10,000 (pulses)] from point A [10,000,0 (pulses)] via point B [10,000, 5,000 (pulses)]. Positioning starts at 3 kpps, but drops to 1 kpps at point B. At point B, bit j+1 (14) turns ON for one scan, and bit j(15) turns ON at point C to indicate completed posi- tioning.
Basic Program Examples Section 8-3 8-3-4 Circular Arc Interpolation (Center Designated) The following program positions a circle counter-clockwise with point C [10,000, 10,000 (pulses)] as the center starting from the origin [0,0 (pulses)] at 2 kpps. At the origin, bit j+2 (15) turns ON to indicate completed position- ing.
Basic Program Examples Section 8-3 8-3-5 Circular Arc Interpolation (Intermediate Point Designated) The following program positions a circle counter-clockwise with point C [10,000, 10,000 (pulses)] as the intermediate point starting from the origin [0,0 (pulses)] at 2 kpps. With intermediate point D [0, 10,000 (pulses)] inter- polation proceeds to point C at 2 kpps.
Basic Program Examples Section 8-3 8-3-6 Continuous Positioning This program is a continuous program of all positioning from subsections 8-3-1 through 8-3-5. Positioning follows the order (1)-(5) as shown in the fig- ure. However, at point A, bit j+5 (15) turns ON for one scan; at point B, bit j+5 (14) turns ON for one scan;...
Page 122
Basic Program Examples Section 8-3 Ladder Diagram j+5(00) l+4(00) j+5(07) DIFU(13) j+5(01) DIFU(13) j+5(14) Start input Origin j+5(01) j+5(03) l(15) l+10(08) CMP(20) WRIT(87) j+5(02) Positioning l+14 Point C Command #0002 Start command to Completed Ready point A #0021 DM m 25506 (08) j+5(08)
Application Program Examples Section 8-4 Application Program Examples 8-4-1 Digital Switch Positioning With this program, you set X-axis coordinates, Y-axis coordinates, and speeds with digital switches. Positioning occurs at the set positions when the start switch is turned on. At the positioning point, the motors stop and the M code 55 is output.
Page 124
Application Program Examples Section 8-4 Data Written to DM Area DM Wd X-axis position (leftmost digits) X-axis position (rightmost digits) Y-axis position (leftmost digits) Y-axis position (rightmost digits) p+10 p+11 p+12 p+13 p+14 p+15 p+16 p+17 p+18 p+19 p+20 p+21 Speed (leftmost digits) p+22 Speed (rightmost digits)
Application Program Examples Section 8-4 8-4-2 Circular Arc Positioning In this example, the center is already determined, but the digital switches de- termine the arc radius. The center has been determined at (2,500, 2,500). Set the radius with the digital switches. The axes then construct the pre- scribed circle starting at the origin and returning to the origin at a speed of 1 pps.
Page 127
Application Program Examples Section 8-4 DM Area Data Allocations DM Wd r+10 r+11 Circular arc center r+12 r+13 r+14 r+15 Circular r+16 arc end r+17 r+18 r+19 r+20 r+21 r+22 r+23 r+24 r+25 r+26 r+27 r+28 r+29 r+30 r+31 r+32 r+33 r+34 r+35...
Page 128
Application Program Examples Section 8-4 DM Wd r+40 r+41 5000 R r+42 r+43 r+44 r+45 r+46 r+47 5000 R r+48 r+49 r+50 r+51 r+52 r+53 r+54 r+55 r+56 r+57 5000 R r+58 r+59 r+60 r+61 r+62 5000 R r+63 r+64 r+65 r+66 r+67...
Application Program Examples Section 8-4 8-4-3 Multiple Positioning This program consecutively executes 25 positioning actions. At each posi- tion, an M code is output to indicate arrival. By turning ON the start switch, the motor axes follow the course along the broken lines in the figure below and perform 25 positioning actions.
Page 131
Application Program Examples Section 8-4 DM Area Allocations Data Area DM Wd b 11 -b t+10 t+11 t+12 t+13 t+14 t+15 t+16 t+17 t+18 t+19 t+20 t+21 t+22 t+23 t+24 t+25 t+26 t+27 t+28 t+29 t+30 t+31 t+32 t+33 t+34 t+35 t+36 t+37...
External Display Section 9-1 External Display This section provides only an overview of the External Display. Refer to the Operation Manual. Front Panel Axis indicator Indicates X- or Y-axis display during Status mode. Current address Displays the current address during Status mode. M code Displays M code during Status mode.
Display Descriptions Section 9-2 Display Descriptions Power ON Operation Press the RESET switch once after turning on the power. The display shows a series of dashes until the origin has been established (See Section 7 Es- tablishing the Origin). If the display is dark, check the following. 1, 2, 3...
Display Descriptions Section 9-2 X-Axis Status and Y-Axis Display various fields of positioning actions and flags of the AR area. The Status Modes display is the same for both axes, although information for only one axis can be displayed at a time. AXIS Designates the axis being displayed: 1: X axis;...
Switches and Indicators Section 9-3 Switches and Indicators Position Control Unit Front The front panel of the Position Control Unit is arranged for connections to the Panel Teaching Box (see operation manual), the External Display (see Section 11), the servomotor drivers (see specifications in Appendix C), external input switches, etc.
Communications Errors Section 10-5 10-1 Procedure Error processing is facilitated by the ERROR LED on the Position Control Unit and error code displays on the External Display. The following figure de- scribes the different error processing steps. The three types of errors, system errors, command/data errors, and communications errors, are further classi- fied by their unique error codes (Refer to Appendix D).
Appendix A Position Control Unit Specifications General Specifications Item Specification Power supply voltage 5 VDC (for PCU) 24 VDC (for external power) Voltage fluctuation tolerance 4.75-5.25 VDC (for PCU) 21.6-26.4 VDC (for external unit power) DC current consumption 950 mA or less for 5 VDC 50 mA or less for 24 VDC Dielectric resistance Between all external terminals and frame ground: 500 VAC for 1...
Page 144
Appendix A Position Control Unit Specifications Dimensions (Unit: mm) 34.5 Connecting cable I/O Electrical Specifications – Inputs Item Specification Input types Origin, external interrupt, CW limit, CCW limit, Emergency stop 24 VDC 10% Input voltage Input current 8 mA ON voltage 12V min.
Page 145
Appendix A Position Control Unit Specifications I/O Electrical Specifications – Outputs Item Specification Output types OUT1, OUT2 Maximum open/close capacity Open collector 40 mA at 24 VDC Leak current 0.1 mA or less Residual voltage 1.1 V or less ± External power supply voltage 24 VDC Output type...
Appendix A Position Control Unit Specifications Performance Specifications Item Specification Control method Semi-closed loop with incremental encoder No. of control axes No. of points used by I/O 32 points (2 words) Peripheral devices Teaching Box, External Display Settings (1) From the Teaching Box (2)From the PC with sequence programs Position types Incremental or absolute...
Appendix B External Display Specifications Item Specification Power supply voltage 100/200 VAC (switch), 50/60 Hz Voltage fluctuation tolerance 90-110 VAC (for 100 VAC) 180-220 VAC (for 200 VAC) Power consumption 100 VA or less Dielectric impedance Between all AC external terminals and frame ground: 50 MW or greater (at 500 VDC) Dielectric resistance Between all external terminals and frame ground:...
Page 149
Appendix C Error Code List System Errors Error Error type Time checked Causes of abnormalities Correction code and status RAM error RAM abnormality in hard- ware. Hardware Common RAM Common RAM abnormal- At power ON error error ity in hardware. Gate array error Gate array abnormality in The user cannot correct these...
Page 150
Appendix C Error Code List Command Errors Error Error Type Time checked Cause of abnormalities and Correction Code status OP code Undefined error When An undefined OP code was sent Correct the OP code and errors commands are as a command. re-transmit the transferred.
Page 151
Appendix C Error Code List Error Error Type Time checked Cause of abnormalities and Correction Code status Speed 0 error When SRT, The speed called in the Check the speeds or ORG, or JOG is positioning action was 0. speed fields of the posi- transferred.
Page 152
Appendix D Position Action Data Coding Sheets ↔ ↔ ↔ DM Wd Function DM Wd Function DM Wd Function Dwell time #0 Unit: 0-2 (0-9,990) Dwell time #1 Pulse rate: 1.0-0.0001 Dwell time #2 Rotation direction: 0, 1 Dwell time #3 Encoder type: 0-1;...
Page 153
Appendix D Parameter and Positioning Action Data Coding Sheets ↔ ↔ ↔ DM Wd Function DM Wd Function DM Wd Function Positioning Positioning Positioning action #1 action #11 action #21 Positioning Positioning Positioning action #2 action #12 action #22 Positioning Positioning Positioning action #3...
Page 154
Appendix D Parameter and Positioning Action Data Coding Sheets ↔ ↔ ↔ DM Wd Function DM Wd Function DM Wd Function Speed #0 Speed #16 Speed #32 (1-300,000) Speed #1 Speed #17 Speed #33 Speed #2 Speed #18 Speed #34 Speed #3 Speed #19 Speed #35...
Glossary absolute position A position given in respect to the origin rather than in respect to the present position. attribute One of several types of data that define positioning actions. Attributes include settings such as interpolation code, interpolation point, and completion code. backlash compensation Compensation for the amount of mechanical play, or “looseness,”...
Page 156
Glossary flag A bit that is turned ON and OFF automatically by the system to provide status information. gain The increase in signal power produced by an amplifier. hunting The tendency, in servosystems, to overcompensate when the system’s momentum carries it past the target position. inching Manual feeding wherein positioning is executed one pulse at a time.
Page 157
Glossary Special I/O Unit A dedicated Unit, such as a Position Control Unit, High-Speed Counter Unit, or Analog Timer Unit, which is used for a special purpose. straight-line interpolation Dual-axis, linear positioning from the present position to a point designated as the interpolation end point.
Index data acceleration and deceleration times, 2, 39 allocations, 29 addresses and channels for, 48 backup, 2 allocations for, 29 capacity and storage, 2 for positioning actions, 43 communication between PC and PCU, 58 setting of, 46 Intelligent I/O Read and Write instructions, 59 configuration, 2, 27 acceleration and deceleration zones, 36 setting sequence, 28...
Page 159
Index origin flags compensation, 38, 100 allocation, 59 search, 38, 98 changes, 77–79 search patterns, 98 during JOG operations, 78 origin search during origin search, 78 acceleration and deceleration, 40 during positioning, 77 addresses for parameters, 98 error code, 71–79 high and low speed, 98 IR area, 66 high speed, 39...
Page 160
Index programming examples speeds continuous positioning, 113 application, 49 changes, for positioning, 44 data transmission from PC to Position Control Unit, 101 current address, 77 ladder diagram, 107 data format, 49 data transmission from Position Control Unit to PC, 111, 112 for positioning actions, 42 reading data, 108 maximum, 37...
Pages 5, 6: C500-ND201 and Non-transformer Power Supply Units deleted from system configuration. Page 10: 1-7 Precautions When Using C500-NC222-E in NC221 Mode added. Pages 18, 19: Motor Driver connection examples changed. Page 27: Gain description changed and added to.