Omron R88A-MCW151-E, R88A-MCW151-DRT-E OPERATION MANUAL
Cat. No. I203-E2-02
R88A-MCW151-E
R88A-MCW151-DRT-E
Motion Control Option
Board
OPERATION MANUAL
MCW151 Series
Motion Control Option Board
Models: R88A-MCW151-E
R88A-MCW151-DRT-E
Operation Manual
Produced March 2003
Notice:
OMRON products are manufactured for use according to proper procedu res by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injur y to p eople or damage to property.
!DANGER
!WARNING
!Caution
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to
an OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch”, which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PC” means Programmable Controller and is not used a s an abbreviation for anything else.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of
information.
Note In dicates information of par ticular interest for efficient and convenient opera-
tion of the product.
1,2,3... Indicates lists of one sort or another, such as procedures, checklists, etc.
Trademarks and Copyrights
DeviceNet is a registered trademark of the Open DeviceNet Vendor Association, Inc.
OMRON, 2003
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in
any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior
written permission of 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. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages
resulting from the use of the information conta ined in this publication.
v
vi
About this Manual:
This manual descri bes the installation and operation o f the R88A-MCW151-E an d R88A-MCW151DRT-E Motion Control Option Boards (MC Units) and includes the sections described below.
Please read this manual and the related manuals listed in the following table carefully and be sure you
understand the information provided before attempting to install or operate the MC Unit. Be sure to
read the precautions provided in the following section.
Name Cat. No. Contents
MCW151 Series
R88A-MCW151-E
R88A-MCW151-DRT-E
Operation Manual
OMNUC W-series
R88M-W
R88D-W
User’s manual
DeviceNet Operation Manual W267 Describes the conf iguration and construct ion of a DeviceNet net-
DeviceNet Conf igurator Operation Manual
❏ (AC Servomotors)
❏ (AC Servo Drivers)
I203 Describes the instal lation and operation of the R88A-MCW151-E
and MCW151-DRT-E Motion Control Units.
(This manua l)
I531 Describes the inst al lation a nd oper ati on of t he W -seri es Servo Dri ver
and Servomotor.
work, including installation procedures and specifications for cables,
connectors, and other connection devices, as well as information on
the communic ations power supply.
W328 Describes the operation of the DeviceNet Configurator to allocate
remote I/O areas according to application needs, as well as procedures to set up a DeviceNet network with more than one master.
Precautions provides general precautions for using the MC Unit and related devices.
Section 1
describes the features and system configuration of the R88A-MCW151-E and R88A-
MCW151-DRT-E Motion Control Units and concepts related to their operation.
Section 2
Section 3
describes the MC Unit components and provides the information for installing the MC Unit.
describes the different Motion Control features of the MCW151. Also the functiona lity of the
Servo Driver related commands are explained.
Section 4
describes the com munication componen ts of the MCW 151-E and MCW151-DRT-E. The
functionality of the serial communication protocols and the DeviceNet interface are explained.
Section 5
provides an overview of the fundamentals of multitasking BASIC progr a ms and the methods
by which programs are managed in the MC Unit.
Section 6
describes all commands, functions and parameters required for programing the motion con-
trol application using the MC Unit.
Section 7
describes the operation of the Motion Perfect programming software package. Motion Per-
fect provides the user a tool to program, monitor and debug motion based applications for the MC Unit.
Section 8
describes error processing and troubleshooting procedures needed to keep the system
operating properly.
Section 9
explains the maintenance and inspec tion procedures that must b e followed to keep the M C
Unit operating in optimum condition. It also includes proper procedures when replacing an MC Unit.
The Appendices provide the required p arameter settings for the Ser vo Driver, the DeviceNet protocol
specification and some general programming examples.
!WARNING
Failure to read and understand the information pro vided in this manual may result in personal injury or death, damage to t he product, or product failure. Pleas e read each section
in its entirety and be sure you unders tand the information provided in the section and
related sections before attempting any of the procedures or operations given.
vii
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
3 General Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
4 Storage and Transportation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
5 Installation and Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
6 Operation and Adjustment Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
7 Maintenance and Inspection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
8 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
SECTION 1
Features and System Configuration . . . . . . . . . . . . . . . . 1
1-1 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Motion Control Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-4 Control System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-6 Comparison between Firmware Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2-1 Components and Unit Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2-3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2-4 Servo System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2-5 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 3
Motion Control Functions . . . . . . . . . . . . . . . . . . . . . . . . 43
3-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3-2 System Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-3 System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 4
Communication Interfaces. . . . . . . . . . . . . . . . . . . . . . . . 59
4-1 Serial Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4-2 DeviceNe t (MCW151-DRT -E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ix
TABLE OF CONTENTS
SECTION 5
Multitasking BASIC Programming . . . . . . . . . . . . . . . . . 85
5-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5-2 BASIC Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5-3 Motion Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5-4 Command Line Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5-5 BASIC Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5-6 Task Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5-7 Error Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SECTION 6
BASIC Motion Control Programm ing Langua ge . . . . . 97
6-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6-2 Command Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6-3 Command, function and parameter description. . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SECTION 7
Motion Perfect Software Package . . . . . . . . . . . . . . . . . . 197
7-1 Features and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7-2 Connecting to the MC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7-3 Motion Perfect Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7-4 Desktop Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7-5 Motion Perfect Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7-6 Suggestions and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
SECTION 8
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
8-1 Error Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8-2 Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8-3 Problems and Countermeasures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
SECTION 9
Maintenance and Inspection. . . . . . . . . . . . . . . . . . . . . . . 233
9-1 Routine Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
9-2 Replacing a MC Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Appendices
Appendix A Servo Driver Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Appendix B Device Protocol (MCW151-DRT-E only). . . . . . . . . . . . . . . . . . . . . . . 239
Appendix C Programming Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
x
PRECAUTIONS
This section provides general precautions for using the Motion Control Unit and related devices.
The information contained in this section is important for the safe and reliable application of the Motio n Control
Unit. You must read this section and u nderstand the information contained before attempting to set up or o perate
a Motion Control Unit and Servo Dri ver.
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
3 General Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
4 Storage and Transportation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
5 Installation and Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
6 Operation and Adjustment Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
7 Maintenance and Inspection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
8 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
8-1 Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
8-1-1 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
xi
Intended Audience 1
1 Intended Audience
This manual is intended for the following personnel, who must a lso have knowledge of el ectr ical systems (an electrical engineer or the equivalent).
• Personnel in charge of installing FA systems.
• Personnel in charge of designing FA systems.
• Personnel in charge of managing FA systems and facilities.
2 General Precautions
The user must operate t he product accordi ng to the perfor mance specifications described in
the operation manuals. You should assume t hat anything not des cribed in this manual is not
possible.
Before using the product under the following conditions, consult your OMRON representative,
make sure the ratings and performance characteristics of the products are good enough for
the systems, machines, or equipment, and be sure to provide the systems, machines, or
equipment with double safety mechanisms.
1. Conditions not described in the manual.
2. The application of the product to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, or safety
equipment.
3. The application of the product to systems, machines, or equipment that may have a serious
influence on human life and property if they are used improperly.
!WARNING
It is extremely important that Mot ion Control Units and related devices be used for the
specified purpose and under the specif ied conditions, especially in applications that can
directly or indirectly affect human life. You must consult with your OMRON representative
before applying Motion Control Units an d related devices to the above mentione d applications.
3 General Warnings and Safety Precautions
Observe the following warnings when using the MC Unit and all pheripheral devices.
Consult your OMRON representative when using the product after a long period of storage.
!WARNING
!WARNING
!WARNING
!WARNING
!WARNING
Always connect the frame ground terminals of the S ervo Dr iver and the Servomotor to a
class-3 ground (to 100 Ω or less). Not connecting to a class-3 ground may result in electric shock.
The product contains dangerous high voltage inside. Tur n OF F the power and wait for at
least five minutes to allow power to discharge before handling or working with the product.
Do not touch the inside of the Servo Driver. Doing so may result in electric shock.
Do not remove the front cover, terminal covers, cables, Parameter Units, or optional
items while the power is being supplied. Doing so may result in electric shock.
Installation, operation, maintenance, or inspection must be performed by authorized per-
sonnel. Not doing so may result in electric shock or injury.
!WARNING
!WARNING
xii
Wiring or inspection must not be performed for at least five minutes after turning OFF the
power supply. Doing so may result in electric shock.
Do not damage, press, or put excessive stress or heavy objects on the cables. Doing so
may result in electric shock, stopping operation of the product, or burning.
General Warnings and Safety Precautions 3
!WARNING
!WARNING
!WARNING
!WARNING
Do not touch the rotating par ts of the Servomotor in operation. Doing so m ay result in
injury.
Do not modify the product. Doing so may result in injury or damage to the product.
Provide safety measures in external control circuits (i.e., not in the MC Unit) to ensure
safety in the system if an abnormality occurs due to malfunction of the MC Unit, incorrect
or unintended configuration and programming of the MC Unit or external factors affecting
the operation of the MC Unit. Not providing sufficient safety measures may result in serious accidents, or property damage.
• The MC Unit ou tputs m ay remain ON or OFF due to deposits on or burning of th e out put relays, or destruction of the output transistors. As a counter-measure for such problems, external safety measures must be provided to ensure safety in the system.
• Provide an external em ergency stopping device that allows an i nstantaneous stop of
operation and power interruption. Not doing so may result in injury.
• Emergency stop circuits, interlock circuits, limit circuits, and similar safety measures
must be provided in external control circuits.
• When the 24 -VDC output (service power supply to the Unit) is overloaded or short-circuited, the voltage may drop and result in the output s being turned OFF. As a countermeasure for such problems, external safety measures must be provided to ensure
safety in the system.
It is the nature of high speed motion control and mot ion control language programming
and multi-tasking systems, that it is not always possible for the system to validate the
inputs to the functions or to validate the combination of functions.
!WARNING
!Caution
!Caution
!Caution
!Caution
It is t he responsibi li ty of the prog rammer to e n s u re that the various BASIC statements are
invoked correctly with the correct number of parameters and inputs, that the values are
correctly validated prior to the actual calling of the functions, and that the BASIC program(s) provide the desired functionality for the application. Failure to do so may result in
unexpected behaviour, loss or damage to the machinery.
When the SERVO_PERIOD parameter has been s et t o change the ser vo cycle pe riod of
the MC Unit, a power down or software reset (using DRV_RESET) must be performed for
the complete system. Not doing so may result in undefined behaviour.
Use the Servomotors and Servo Drivers in a specified combination. Using them incorrectly may result in fire or damage to the product.
Do not operate the control system in the following locations:
• Locations subject to direct sunlight.
• Locations subject to temperat ures or hum idity out side the ra nge spec ified in th e spec i-
fications.
• Locations subject to condensation due to radical temperature changes.
• Locations subject to corrosive or inflammable gases.
• Locations subject to dust (especially iron dust) or salts.
• Locations subject to vibration or shock.
• Locations subject to exposure to water, oil or chemicals.
Do not touch the Servo Driver radiator, Regeneration Resistor, or Servomotor while the
power is being supplied or soon after power is turned OFF. Doing so may result in a skin
burn due to the hot surface.
xiii
Storage and Transportation Precau tions 4
4 Storage and Tran sportation Precautions
!Caution
!Caution
!Caution
Do not hold the product by the cables or motor shaft while transporting it. Doing so may
result in injury or malfunction.
Do not place any load exceeding the figure indicated on the product. Doing so may result
in injury or malfunction.
Use the motor eye-bolts only for transporting the M otor. Using them for transporting the
machine ry may resu lt in in j u ry or malf u nc ti o n .
5 Installation and Wiring Precautions
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
Do not step or place a heavy object on the product. Doing so may result in injury.
Do not cover the inlet or outlet ports and prevent any foreign objects from entering the
product. Doing so may result in fire.
Be sure to install the product in the right direction. Not doing so may result in malfunction.
Provide the specified clearance between the Servo Driver and the control panel or with
other devices. Not doing so may result in fire or malfunction.
Do not apply any strong impact. Doing so may result in malfunction.
Be sure to wire correc tly and sec urely. Not doing so may result in motor r unaway, injury,
or malfunction.
Be sure that all mounting screws, term inal sc rews, and cable connector screws are tight-
ened securely. Incorrect tightening may result in malfunction.
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
Use crimp ter minals for wiring. Do not connect b are stranded wires directly to ter minals.
Connection of bare stranded wires may result in fire.
Always use the power supply voltages specified in the manual. An incorrect voltage may
result in malfunction or burning.
Take appropr iate m eas ures t o en su re that the spec ified power with the rated voltage a nd
frequency is supplied. Be par ticularly careful in places wh ere the power suppl y is unstable. An incorrect power supply may result in malfunction.
Install external breakers and take other safety measures against short-circuiting in external wiring. Insufficient safety measures against short-circuiting may result in burning.
Take appropriate and sufficient countermeasures when installing systems in the following
locations. Not doing so may result in damage to the product.
• Locations subject to static electricity or other sources of noise.
• Locations subject to strong electromagnetic fields.
• Locations subject to possible exposure to radiation.
• Locations near power supply lines.
Do not reverse the polarity of the battery when connect ing it. Reversing the polarity may
damage the battery or cause it to explode.
Before touching a Unit, be sure to first touch a grounded metallic objec t in order to discharge any static build-up. Not doing so may result in malfunction or damage.
xiv
Operation and Adjustment Precautions 6
6 Opera tion an d A djustment Pre c autio ns
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
!Caution
Confirm that no adverse effects will occur in the system before performing the test operation. Not doing so may result in damage to the product.
Check the modified user programs, newly set parameters and switches for proper execution before actually running them. Not doing so may result in damage to the product.
Do not make any extreme adjustment s or s ett ing ch anges. Do ing so m ay result in uns table operation and injury.
Separate the Servomotor from the ma chine, check for proper operation, and then connect to the machine. Not doing so may cause injury.
When an a larm occurs, remove the cau se, reset the alarm after confirming safety, a nd
then resume operation. Not doing so may result in injury.
Do not come close to the machine immediately after resetting momentary power interruption to avoid an unexpected restart. (Take appropriate measures to secure safety against
an unexpected restart.) Doing so may result in injury.
Confirm that no adverse effect will occur in the system before attempting any of the following. Not doing so may result in an unexpected operation or damage to the product.
• Changing the present values or set values.
• Changing the parameters.
• Modifying (one of) the application programs.
Do not save data into the flash memory duri ng memory operation or while the motor is
running. Otherwise, unexpected operation may be caused.
!Caution
!Caution
!Caution
Do not turn OFF the power supply to the Unit while data is being written to flash memory.
Doing so may cause problems with the flash memory.
Do not turn OFF the power supply to the Unit while data is being t ransferred. Doing so
may result in malfunction or damage to the product.
Do not download any firmware to the MC Unit that has not been distributed by OMRON or
that has not been authorized and approved by OMRON for downloading into the
MCW151 series. Failure to do so may result in permanent or temporar y malfunction of
the Unit or unexpected behaviour .
7 Maintenance and Inspection Precautions
!WARNING
!Caution
Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so may
result in malfunction, fire, electric shock, or injury.
Resume operation only after transferring to the new Unit the contents of the data required
for operation. Not doing so may result in an unexpected operation or damage to the product.
8 Conformance to EC Directives
Applicable Directives
• EMC Directives
• Low Voltage Directive
xv
Conformance to EC Directives 8
8-1 Concepts
EMC Directives
OMRON devices that comply with EC Directives also conform to the related E MC standards
so that they can be more easil y built into other devices or ma-chines. The actua l products
have been checked for conformity to EMC standards (see the following note). Whether the
products conform to the standards in the system used by the customer, however, must be
checked by the customer. EMC-related performance of th e OMRON devices that comply with
EC Directives will vary depending on the configuration, wiring, and other conditions of the
equipment or con trol panel in which the OMRON devices are installed. The customer must,
therefore, perform final checks to confirm that devices and the over-all machine conform to
EMC standards.
Note Applicable EMC (Electromagnetic Compatibility) standards are as follows:
EMS (Electromagnetic Susceptibility): EN61000-6-2, EN50082-2
EMI (Electromagnetic Interference): E N55011 Class A Group 1
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 VAC or 75 to 1,500 VDC meet
the required safety standards.
8-1-1 Conformance to EC Directives
The W-series Servo Driver complies with EC Directives. To ensure that the machine or device
in which a Ser vo Dr iver and MC Unit are used complies with EC directives, the Servo System
must be installed as follows (refer to OMNUC W-series User’s manual (I531)):
1,2,3... 1. The Servo Driver must be mounted in a metal case (control box). (It is not necessary to
mount the Servomotor in a metal box.)
2. Noise filters and surge absorbers must be inserted in power supply lines.
3. Shielded cable must be used for I/O signal cables and encoder cables. (Use soft steel wire.)
4. Cables leading out from the control box must be enclosed within metal ducts or conduits
with blades.
5. Ferrite cores must be installed for cables with braided shields, an d the shield must be directly grounded to a ground plate.
xvi
SECTION 1
Features and System Configuration
This section describes the features and system configuration of the R88A-MCW151-E and R88A-MCW151-DRT-E
Motion Control Units and concepts related to their operation.
1-1 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-2 Description of Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Motion Control Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-3-1 PTP-control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-3-2 CP-control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-3-3 EG-Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1-3-4 Other Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1-4 Control System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1-4-1 Servo System Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1-4-2 Encoder Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-5-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-5-2 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-5-3 DeviceNet Specifications (MCW151-DRT-E only) . . . . . . . . . . . . . 21
1-6 Comparison between Firmware Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1
Features Section 1-1
1-1 Features
MCW151-E MCW151-DRT-E
1-1-1 Overview
MCW151
RUN STS
SD RD
1
25
PORT0 ,1
PORT2
2
I/O
26
+24V
0V
MCW151-DRT
RUNMSSTS
1
25
NS
PORT0,1
2
I/O
26
+24V
0V
The R88A-MCW151 is a 1.5-axis Motion Control (MC) Unit which is connected to the W-series Servo Driver. The MC Unit provides direct control of
the Servo Driver, enables both speed and torque control and has ac cess to
detailed Servo Driver data. To support a multi-axis control application, the MC
Unit features both an encoder input and output connection.
There are two types of the MCW151 Motion Controllers, according to the
communication interface which is integrated into the Unit.
Communication Interface Model
RS-422A/485 Serial Communication R88A-MCW151-E
DeviceNet R88A-MCW151-DRT-E
The multi-tasking BASIC motion control language provides an easy to use
tool for programming advanced motion control applications.
Three types of motion control are possible: point-to-point, continuous path
and electronic gearing.
Point-to-point Control Point-to-point (PTP) control enables positioning independently for each axis.
Axis specific parameters and c ommands are us ed to determi ne the p aths for
the axes.
Continuous Path Control Continuous path (CP) control enables the user not only to control the start and
end positions, but also the path between those points. Possible multi-axis
paths are linear interpolation and circular interpolation. Also user defined
paths can be realized with the CAM control.
Electronic Gearing Electronic gearing (EG ) enables controlling an axis as a direct li nk to another
axis. The MC Units supports electronic gear boxing, linked moves and CAM
movements and adding all movements of one axis to another.
2
Features Section 1-1
1-1-2 Descr iption of Features
The MC Unit provides the following features.
Motion Control The direct connection to the Servo Driver provides a high performance / high
precision control system. Operation will be processed in optimal synchronization.
• Suppor t s both speed and torque co ntrol modes of the Servo Dr iver.
• Supports switching between the modes during operation.
• Suppor t s speed limit during torque con trol using the speed reference.
• Selectable MC Unit servo period cy cle which can be set to either 0.5 ms
or 1.0 m s.
Servo Driver Access Apart from the motion control operation with the Servo Driver, the MC Unit
provides the following features:
• Monitor the detailed Servo Driver alarm status.
• Monitor various monitor signals (rotation speed, command torque).
• Monitor the Servo Driver digital inputs and a nalog input to i nclude in the
application.
• Read and write of the Servo Driver Parameters.
• Execution of several Driver functions from the MC Unit. Examples are
Print Registration, Origin Search, Driver Alarm Reset and Driver Reset.
Easy Programming with
BASIC Motion Control
Language
Encoder Input and Output To achieve a solution for multi-axis applications, the M C Unit is provided wi th
DeviceNet Interface
(MCW151-DRT-E only)
Serial Communications The MC Unit has three (MCW151-E ) or two (MCW151-DRT-E ) seri al ports for
The multi-task BASIC motion control language is used to program the MC
Unit. A total of 14 programs can be held in the Unit and up to 3 tasks can be
run simultaneously. The MC Unit is programmed using a Windows-based
application called
programming and debugging.
an encoder axis. This axis provides either to have an encoder input for external encoders or to have an encoder output to cascade position data to
another MC Unit.
The MCW151-DRT-E can be connected easily in an existing DeviceNet network. The DeviceNet network has a maximum communication distance of
500 m, so an MC Unit in a remote location can be controlled from the Master.
The MC Unit supports both remote I/O and explicit message communications.
• Remote I/O communications
Remote I/O communications can exchange data (4 input words and 4 output words max.) with the MC Unit at high speed and without programming, just like regular I/O.
• Explicit message commun ications
Large data transfers to a nd from t he M C Unit m emor y can be perform ed
by sending explicit messages from the Master when required.
communication to several external devices. Next to the connection to th e Personal Computer for configuring, the MC Unit can be connected with PCs, Programming Ter minals (PTs) and other MC Units. The serial ports suppor t the
Host Link Master and Slave protocols.
1
Motion Perfect. Motion Perfect allows extremely flexible
Absolute Encoder
Support
By using a S ervomotor with absol ute encoder, the motor position is updat ed
automatically in the MC Unit at start-up of the system. No origin search
sequence will be necessary in the system initiation phase.
1.Motion Perfect is a product of Trio Motion Technology Limited.
3
Features Section 1-1
Virtual Axes The MC Unit contains a total of 3 axes, of which two can be configured as vir-
tual axis. The virtual axes are internal axes and are used for computational
purposes. They act as perfect servo axes and are very useful for creating profiles. They can be linked directly to the servo axes.
Hardware-based
Registration Inputs
There is a high-speed registration input for the encoder inp ut and out put axis.
On the rising or falling edge of a regi stration input, th e MC Unit will store the
current position in a register. The registered position can then be used by the
BASIC program as required. T he registered positions are captured in hardware.
General-purpose Input
and Output Signals
Starting, st opping, limit switching, origin sea rches and many other f unctions
can be controlled by the MC Unit. The general I/O can have specific functions
(such as the registration, limit switches), but also can be freely used.
Reduced Machine Wear The traditional trap ezoidal speed prof ile is provided t o ge nerate sm oot h st art-
ing and stopping. The trapezoidal corners can be rounded off to S-curves.
Trapezoidal Speed Profile with
Square Corners
Time
Trapezoidal Speed Profile with
S-curveCorners
SpeedSpeed
Time
4
System Configuration Section 1-2
1-2 System Configuration
Basic Configuration
W-series Servo Driver MCW151
Personal Computer running Motion Perfect
MCW151
STS
RUN
SD
RD
PORT2 PO RT0 ,1
1
2
I/O
25
26
+24V
0V
Typical applicable Sensors for Servo
Driver Digital I nputs
Print Registration
Personal
Computer
1
Typicalapplicable Units for Serial Comm. Ports
PC
2
Programmable
Terminal (PT)
General-purpose
device
Typical applicable Actuators for Digital O utputs
Relais
Lamp
Limit Switches
Power Supply connection
24 V Power supply
Typicalapplicable Pulse Generators for
Encoder Input
MCW151 Unit
Servo Driver
Note 1. The RS-422A/485 Serial Port 2 is only available on the MCW151-E Unit.
2. The MC Unit has one encoder axis. Either the encoder input or the encoder
Typical applicable Sensors for Digital Inputs
Print Registration
Proximity Sensor
Typical applicable Units f or Encoder Output
MCW151 Unit
output can be used.
5
System Configuration Section 1-2
The equipment and models which can be used in the system configuration
are shown in the following table.
Device Model
Motion Control Unit R88A-MCW151-E
R88A-MCW151-DRT-E
Servo Driver (see note) R88D-WT
Servomotor
Control De vices (using
Host Link)
Personal Computer (for
Motion Perfect)
Motion Perfect Version 2.0 or later
R88M-W
Prog ramma bl e Terminals
CPU Units
IBM Pers onal Computer or 100% compatible
Note The MC Unit must be used with a Servo Driver with software version 14 or
later. The MC Unit cannot be used with software version 8.
❏
❏
DeviceNet Configuration
(MCW151-DRT-E only)
A DeviceNet system can be constructed in two ways: fixed allocation or free
allocation.
Fixed Allocation
A DeviceNet system can be constructed easily without the Configurator. With
fixed allocation, predetermined words are allocated to each node for the
Slave’s I/O.
An OMRON Master must be used in order to perform fixed allocation. Moreover, with fixed allocation only one M aster Unit can be u sed in a DeviceNet
network and only one Master Unit may be mounted to a PC.
Master Unit
CPU Unit
Remote I/O communications
Slave Slave MC Unit
Free Allocatio n
The Configurator can be used to freely allocate the words used by each
Slave. With free allocation, more than one Master Unit can be connected in a
DeviceNet network and each Master’s Slave I/O can be set independently.
More than one Master Unit may be mounted to each PC and those Masters
can be used independently. Furthermore, other compan ies’ Masters can be
6
Motion Control Concepts Section 1-3
used. For details, refer to the DeviceNet Configurator Operation Manual
(W328).
Master Unit Master Unit
CPU Unit
Remote I/O communications
MC Unit
Slave
Master Unit
Message
communications
Slave
MC Unit
The following OMRON Master Units can be used.
Appli c able P C Ma s te r Un it mo d e l
number
CS1 Series CS1-DRM21 CPU Rack or Expansion I/O Rack
(Classified as Special I/O Units)
C200HZ/HX/HG/HE C200HW-DRM21-V1 CPU Rack or Expansion I/O Rack
(Classified as Special I/O Units)
Mounting position Max. number of Units
Note S om e CPUs can control 16 Master Units and other CPUs can control 10.
With
Configurator
16 1
10 or 16 (see
note)
Configurator
ISA Board
Without
Configurator
1
1-3 Motion Control Concepts
The MC Unit offers the following types positioning control operations.
1. Point-to-point control
2. Continuous Path control
3. Electronic Gearing
This section will introduce some of the commands and parameters as used in
the BASIC programming of the motion control application. Refer to
SECTION 6 BASIC Motion Control Programming Language for details.
Coordinate S ys te m Positioning operations performed by the MC Unit are based on an axis coordi-
nate system. The MC Unit converts the position data from either the connected Servo Driver or the connected encoder into an internal absolute
coordinate system.
The engineering unit which specif ies the distances of travelling can be freely
defined for each axis separately. The conversion is performed through the
use of the unit conversion factor, which is defined by the UNITS axis parameter. The origin point of the coordinate system can be det ermined using the
DEFPOS command. Thi s command re-de fines the current position to zero or
any other value.
A move is defined in either absolute or relative terms. An absolute move takes
the axis to a specific predefined position with respect to the origin point. A relative move takes the axis from the current position to a position that is defined
relative to this current position. The following diagram shows gives an exam-
7
Motion Control Concepts Section 1-3
ple of relative (command MOVE) and absolute (command M OVEABS) linear
moves.
MOVEABS(30)
MOVE(60)
MOVEABS(50)
MOVE(50)
MOVE(30)
1-3-1 PTP-control
In point-to-point positioning, each axi s is moved independently of the other
axis. The MC Unit supports the following operations.
• Relative m o ve
• Absolute move
• Continuous move forward
• Continuous move reverse
Relative and Absolute Moves
To move a single axis either t he command MOVE for a relative move or the
command MOVEABS for an absolute move is used. Each axis has its own
move characteristics, which are defined by the axis parameters.
Suppose a control program is executed to move from the origin to an axis
no. 0 coordinate of 100 and axis no. 1 coordinate of 50. If the speed parameter is set to be the s ame for both axes and the acceleration and dec eleration
rate are set sufficiently high, the m ovements for axis 0 and axis 1 will be as
illustrated below.
Axis 1
0
50
50 100
MOVEABS(100) AXI S(0)
MOVEABS(50) AXIS(1)
Axis position
0
50
100
Axis 0
At start, both the axis 0 and axis 1 will move to a coordinate of 50 over the
same duration of time. At this point, axis 1 will stop and the axis 0 will continue to move to a coordinate of 100.
Relevant Axis Parameters As mentioned before the move of a certain axis is determined by the axis
parameters. Some relevant parameters are given in the next table.
Parameter Description
UNITS Unit conver sion factor
ACCEL Acceleration rate of an axis in units/s
DECEL Deceleration rate of an axis in units/s
SPEED Demand speed of an axis in units/s
2
2
8
Motion Control Concepts Section 1-3
D
d
Defining moves The speed profile below shows a simple MOVE operation. The UNITS param-
eter for this axis has been defined for example as meters. The required maximum speed has been set to 10 m/s. In order to reach this speed in one
second and also t o decelerate to zero speed again i n one second, both the
acceleration as the deceleration rate have been set to 10 m/s
tance travelled is the sum of distances travelled during the acceleration, constant speed and decel eration segm ents. Suppose the di stance moved by the
MOVE command is 40 m, the speed profile will be given by the following
graph.
Speed
10
2
. The total dis-
ACCEL=10
DECEL=10
SPEED=10
MOVE(40)
0
12345
6
Time
The following two speed profiles show the same movement with an acceleration time respectively a deceleration time of 2 seconds.
Speed
ACCEL=5
6
DECEL=10
SPEED=10
MOVE(40)
Time
ACCEL=10
DECEL=5
SPEED=10
MOVE(40)
10
Speed
10
0
12345
0
12345
6
Time
Move Calculations The following equations are used to calculate the total time for the motion of
the axes. Consider the moved distance for the MOVE command as , the
demand speed as , the acceleration rate and deceleration rate .
V
a
9
Motion Control Concepts Section 1-3
Continuous Moves
Acceleration time
V
---=
a
2
Acceleration dist a nc e
V
------=
2a
Deceleratio n time
V
---=
d
2
Deceleration distance
V
------=
2d
Constant speed distance
V2ad+()
D=
-----------------------–
2ad
D
Total time
The FORWARD and REVERSE commands can be used to start a continuous
movement with constant speed on a cert ain axis. The FORWARD command
will move the axis in positive direction and the REVERSE comman d in negative direction. For these commands also the axis parameters ACCEL and
SPEED apply to specify the acceleration rate and demand speed.
Both movements can be canceled by using either the CANCEL or RAPIDSTOP command. The CANCEL command will cancel the m ove for one axis
and RAPIDSTOP will cancel m oves on all axes. The de celeration rate is set
by DECEL.
Va d+()
--- -=
-------------------- -+
V
2ad
1-3-2 CP-control
Linear Interpolation
Continuous Path control enables to control a specif ied p ath bet ween t he st art
and end position of a movement for one or multiple axes. The MC Unit supports the following operations.
• Linear interpolation
• Circular interpolation
• CAM control
In applications it can be required for a set of motors to perform a move operation from one position to another in a straight line. Linearly interpolated moves
can take place among several axes. The commands MOVE and MOVEABS
are also used for the linear int erpola ti on . I n t h is c as e t h e c o m ma nds will h ave
multiple arguments to specify the relative or absolute move for each axis.
Consider the following three axis move in a 3-dimensional plane.
MOVE(50,50,50)
Axis 2
Axis 1
Speed
Time
10
Axis 0
Motion Control Concepts Section 1-3
The speed profile of the motion along the path is given in the diagram. The
three parameters SPEED, ACCEL and DECEL which determine the multi axis
movement are taken from the corresponding parameters of the base axis.
The MOVE command computes the various components of speed demand
per axis.
Circular Interpolation
It may be required that a tool travels from the starting point to the end point in
an arc of a circle. In this instance the motion of two axes is related via a circular interpolated move using the MOVECIRC command. Consider the following
diagram.
CAM Control
MOVECIRC(-100,0,-50,0,0)
-50
The centre point and desired en d point of the trajectory relative to the start
point and the direction of movement are specified. The MOVECIRC command
computes the radius and the angle of rotation . Like the linearly inter polated
MOVE command, the ACCEL, DECEL and SPEED variables associated with
the base axis determine the speed profile along the circular move.
Additional to the standard move profiles the MC Unit also provides a way to
define a position profile for the axis to move. The CAM command will move an
axis according to position values stored in the MC Unit Table array. The
speed of travelling through the profile is determined by the axis parameters of
the axis.
CAM(0,99,100,20)
Axis 1
0
50
50
Axis 0
1-3-3 EG-Control
Position
Time
Electronic Gearing control allows you to create a direct gearbox link or a
linked move between two axes. The MC Unit supports the following operations.
1. Electronic gearbox
2. Linked CAM
3. Linked move
4. Adding axes
11
Motion Control Concepts Section 1-3
Electronic Gearbox
The MC Unit is able to have a gearbox link from one axis to another as if there
is a physical gearbox connecting them. This can be done using the C ONNECT command in the program. In the command the ratio and the axis to link
to are specified.
CONNECT Axis
2:1
Axes Ratio CONNECT command
01
1:1 CONNECT(1,0) AXIS(1)
2:1 CONNECT(2,0) AXIS(1)
1:1
1:2
Master Axis
Linked CAM control
Linked Move
1:2 CONNECT(0.5,0) AXIS(1)
Next to the standard CAM profiling tool the MC Unit also provides a tool to link
the CAM profile to another axis. The command to create the link is called
CAMBOX. The travelling speed through the profile is not deter mined by the
axis parameters of the a xis but by the position of t he linked axis. This is like
connecting two axes through a cam.
CAMBOX(0,99,100,20,0) AXI S(1)
CAMBOX Axis (1) Position
Master Axis (0) Position
The MOVELINK command provides a way to link a specified move to a master axis. The move is divided into an acceleration, dece leration and constant
12
Motion Control Concepts Section 1-3
speed part and they are specified in master link distances. This can be particularly useful for synchronizing two axes for a fixed period.
MOVELINK(50,60,10,10,1) AXIS(0)
Speed
Master Ax is (1)
Synchronized
MOVELINK Axis (0)
Time
Adding Axes
It is very useful to be able to add all movements of one axis to another. One
possible application is for instance changing the offset between two axes
linked by an electronic gearbox. The MC Unit provides this possibility by using
the ADDAX command. The movements of the linked ax is will consists of all
movements of the actual axis plus the a dditional movements of the master
axis.
Speed axis 0*
BASE(0)
ADDAX(2)
FORWARD
MOVE(100) AXIS(2)
MOVE(-60) AXIS(2)
Speed axis 2
Time
+
Speed axis 0
Time
=
Time
1-3-4 Other Operations
Canceling Moves In normal operation or in case of emergency it can be necessary to cancel the
current movement from the buffers. When the CANCEL or RAPIDSTOP commands are given, the selected axis respectively all axes will cancel their current move.
Orig in Sea rch The encoder feedback for controlling the position of the motor is incremental.
This means that all movement must be defined with respect to an origin point.
The DATUM comm and is used to set up a procedure whereby the MC Unit
goes through a sequence and searche s for the origin based on digital inputs
and/or Z-marker from the encoder signal.
13
Control System Configuration Section 1-4
Print Registration The MC Unit can capture t he position of an axis in a regi ster when an event
occurs. The event is referred to as the print registration input. On the risin g or
falling edge of an input signal, which is either the Z-marker or an input, the MC
Unit captures the position of an axis in hardware. This position can then be
used to correct possible error between the actual position and the desired
position. The print registration is set up by using the REGIST command.
The position is captured in hardware, and therefore there is no software overhead and no interrupt service routines, eliminating the nee d to deal with the
associated timing issues.
Merging Move s If the MERGE axis parameter is set to 1, a movement will always be followed
by a subsequent movement without stopping. The following illustrations will
show the transitions of two moves with MERGE value 0 and value 1.
Speed
MERGE=0
Time
Speed
MERGE=1
Time
Jogging Jogging moves the axes at a constant speed forward or reverse by manual
operation of the digital in puts. Different speeds are also selectable by input.
Refer to the FWD_JOG, REV_JOG and FA ST_JOG axis parameters.
1-4 Control System Configuration
1-4-1 Servo System Principles
The servo system used by and the internal operation of the MC Unit are
briefly described in this section. Refer to 2-4 Servo System Precautions fo r
precautions related to servo system operation.
Semi-closed Loop System The servo system of the MC Unit uses a semi-closed or inferred closed loop
system. This system detects actua l m ac hin e movements b y th e ro tation of the
motor in relation to a t arget value. It calculates the error between the target
value and actual movement, and reduces the error through feedback.
14
Control System Configuration Section 1-4
Internal Operation of the
MC Unit
1,2,3... 1. The MC Unit performs actual position c ontrol. The main inpu t of the con-
MC Unit
Servo System
2
3
Demand
position
1
+
-
Position
Control
Speed
reference
Speed
Control
Motor
4
Measured
speed
Encoder
Measured
position
Inferred closed loop systems occupy the mainstream in modern servo systems applied to positioning devices for industrial applications. The following
graph shows the basic principle of the Servo System as used in the MC Unit.
troller is the following error, which is the calculated difference between the
demand position and the actual measured position.
2. The Position Controller calculates the required speed reference output determined by the following error and possibly the dema nded position and
the measured position. The speed reference is provided to the Servo Driver.
3. The Servo Driver controls the rotational speed of the Servomotor corresponding to the speed reference. The rotational speed is proportional to
the speed reference.
4. The rotary encoder wil l generate the feedback pulses for both the speed
feedback within the Servo Driver speed loop and the position feedback
within the MC Unit position loop.
Motion Control Algorithm The servo system controls the m otor by continuously ad justing t he s pee d ref -
erence to the Servo Driver. The speed reference is calculated by the MC
Unit’s Motion Control algorithm, which is explained in this section.
The Motion Control algorithm uses th e demand position, the measured posi tion and the following error to determine the speed reference. The following
error is the difference between the d emanded and measured position. The
demand position, me asured position and following error are represented by
axis parameters MPOS, DPOS and FE. Five gain values have been implemented for the user to be able to configure the correct control operation for
each application.
15
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