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 procedures 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 injury to people or damage to property.

!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

!Caution 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 as 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 Indicates information of particular interest for efficient and convenient operation 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 contained in this publication.

v

vi

About this Manual:

This manual describes the installation and operation of the R88A-MCW151-E and R88A-MCW151- DRT-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	I203	Describes the installation and operation of the R88A-MCW151-E
R88A-MCW151-E		and MCW151-DRT-E Motion Control Units.
R88A-MCW151-DRT-E		(This manual)
Operation Manual
OMNUC W-series	I531	Describes the installation and operation of the W-series Servo Driver
R88M-W (AC Servomotors)		and Servomotor.
R88D-W (AC Servo Drivers)
User’s manual
DeviceNet Operation Manual	W267	Describes the configuration and construction of a DeviceNet net-
		work, including installation procedures and specifications for cables,
		connectors, and other connection devices, as well as information on
		the communications power supply.
DeviceNet Configurator Oper-	W328	Describes the operation of the DeviceNet Configurator to allocate
ation Manual		remote I/O areas according to application needs, as well as proce-
		dures 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 describes the MC Unit components and provides the information for installing the MC Unit. Section 3 describes the different Motion Control features of the MCW151. Also the functionality of the Servo Driver related commands are explained.

Section 4 describes the communication components of the MCW151-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 programs 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 control application using the MC Unit.

Section 7 describes the operation of the Motion Perfect programming software package. Motion Perfect 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 inspection procedures that must be followed to keep the MC Unit operating in optimum condition. It also includes proper procedures when replacing an MC Unit. The Appendices provide the required parameter settings for the Servo Driver, the DeviceNet protocol specification and some general programming examples.

!WARNING Failure to read and understand the information provided in this manual may result in personal injury or death, damage to the product, or product failure. Please read each section in its entirety and be sure you understand 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		DeviceNet (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 Programming Language . . . . .		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 Motion Control Unit. You must read this section and understand the information contained before attempting to set up or operate a Motion Control Unit and Servo Driver.

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 also have knowledge of electrical 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 the product according to the performance specifications described in the operation manuals. You should assume that anything not described 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 Motion Control Units and related devices 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 Motion Control Units and related devices to the above mentioned 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 Always connect the frame ground terminals of the Servo Driver 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.

!WARNING The product contains dangerous high voltage inside. Turn OFF the power and wait for at least five minutes to allow power to discharge before handling or working with the product.

!WARNING

!WARNING

!WARNING

!WARNING

!WARNING

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 personnel. Not doing so may result in electric shock or injury.

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.

xii

General Warnings and Safety Precautions

3

!WARNING

!WARNING

!WARNING

!WARNING

Do not touch the rotating parts of the Servomotor in operation. Doing so may 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 outputs may remain ON or OFF due to deposits on or burning of the output 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 emergency stopping device that allows an instantaneous 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-cir- cuited, the voltage may drop and result in the outputs 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 motion 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 It is the responsibility of the programmer to ensure 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.

!Caution When the SERVO_PERIOD parameter has been set to change the servo cycle period 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.

!Caution Use the Servomotors and Servo Drivers in a specified combination. Using them incorrectly may result in fire or damage to the product.

!Caution Do not operate the control system in the following locations:

•Locations subject to direct sunlight.

•Locations subject to temperatures or humidity outside the range specified in the specifications.

•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.

!Caution 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 Precautions

4

4 Storage and Transportation Precautions

!Caution Do not hold the product by the cables or motor shaft while transporting it. Doing so may result in injury or malfunction.

!Caution Do not place any load exceeding the figure indicated on the product. Doing so may result in injury or malfunction.

!Caution Use the motor eye-bolts only for transporting the Motor. Using them for transporting the machinery may result in injury or malfunction.

5 Installation and Wiring Precautions

!Caution Do not step or place a heavy object on the product. Doing so may result in injury.

!Caution Do not cover the inlet or outlet ports and prevent any foreign objects from entering the product. Doing so may result in fire.

!Caution Be sure to install the product in the right direction. Not doing so may result in malfunction.

!Caution 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.

!Caution Do not apply any strong impact. Doing so may result in malfunction.

!Caution Be sure to wire correctly and securely. Not doing so may result in motor runaway, injury, or malfunction.

!Caution Be sure that all mounting screws, terminal screws, and cable connector screws are tightened securely. Incorrect tightening may result in malfunction.

!Caution Use crimp terminals for wiring. Do not connect bare stranded wires directly to terminals. Connection of bare stranded wires may result in fire.

!Caution Always use the power supply voltages specified in the manual. An incorrect voltage may result in malfunction or burning.

!Caution Take appropriate measures to ensure that the specified power with the rated voltage and frequency is supplied. Be particularly careful in places where the power supply is unstable. An incorrect power supply may result in malfunction.

!Caution Install external breakers and take other safety measures against short-circuiting in external wiring. Insufficient safety measures against short-circuiting may result in burning.

!Caution 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.

!Caution Do not reverse the polarity of the battery when connecting it. Reversing the polarity may damage the battery or cause it to explode.

!Caution Before touching a Unit, be sure to first touch a grounded metallic object in order to discharge any static build-up. Not doing so may result in malfunction or damage.

xiv

Operation and Adjustment Precautions

6

6 Operation and Adjustment Precautions

!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.

!Caution 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.

!Caution Do not make any extreme adjustments or setting changes. Doing so may result in unstable operation and injury.

!Caution Separate the Servomotor from the machine, check for proper operation, and then connect to the machine. Not doing so may cause injury.

!Caution When an alarm occurs, remove the cause, reset the alarm after confirming safety, and then resume operation. Not doing so may result in injury.

!Caution 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.

!Caution 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.

!Caution Do not save data into the flash memory during memory operation or while the motor is running. Otherwise, unexpected operation may be caused.

!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.

!Caution Do not turn OFF the power supply to the Unit while data is being transferred. Doing so may result in malfunction or damage to the product.

!Caution 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 temporary malfunction of the Unit or unexpected behaviour.

7 Maintenance and Inspection Precautions

!WARNING Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so may result in malfunction, fire, electric shock, or injury.

!Caution 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 EMC standards so that they can be more easily built into other devices or ma-chines. The actual 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 the OMRON devices that comply with EC Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control 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):	EN55011 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 Servo Driver 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, and 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
M CW151		MCW151-DRT
RUN	STS	RUN	STS
SD	RD	MS	NS
	PORT0,1		PORT0,1
	PORT2
1	2	1	2
	I/O		I/O
2 5	26	2 5	26
	+ 24 V		+ 2 4V
	0 V		0V

1-1-1	Overview
		The R88A-MCW151 is a 1.5-axis Motion Control (MC) Unit which is con-
		nected to the W-series Servo Driver. The MC Unit provides direct control of
		the Servo Driver, enables both speed and torque control and has access 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 commands are used to determine the paths 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 link 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 Description 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 synchroniza-
	tion.
	• Supports both speed and torque control modes of the Servo Driver.
	• Supports switching between the modes during operation.
	• Supports speed limit during torque control using the speed reference.
	• Selectable MC Unit servo period cycle which can be set to either 0.5 ms
	or 1.0 ms.
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 analog input to include 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	The multi-task BASIC motion control language is used to program the MC
BASIC Motion Control	Unit. A total of 14 programs can be held in the Unit and up to 3 tasks can be
Language	run simultaneously. The MC Unit is programmed using a Windows-based
	application called 1Motion Perfect. Motion Perfect allows extremely flexible
	programming and debugging.
Encoder Input and Output	To achieve a solution for multi-axis applications, the MC Unit is provided with
	an encoder axis. This axis provides either to have an encoder input for exter-
	nal encoders or to have an encoder output to cascade position data to
	another MC Unit.
DeviceNet Interface	The MCW151-DRT-E can be connected easily in an existing DeviceNet net-
(MCW151-DRT-E only)	work. 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 out-
	put words max.) with the MC Unit at high speed and without program-
	ming, just like regular I/O.
	• Explicit message communications
	Large data transfers to and from the MC Unit memory can be performed
	by sending explicit messages from the Master when required.
Serial Communications	The MC Unit has three (MCW151-E) or two (MCW151-DRT-E) serial ports for
	communication to several external devices. Next to the connection to the Per-
	sonal Computer for configuring, the MC Unit can be connected with PCs, Pro-
	gramming Terminals (PTs) and other MC Units. The serial ports support the
	Host Link Master and Slave protocols.
Absolute Encoder	By using a Servomotor with absolute encoder, the motor position is updated
Support	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 pro-
	files. They can be linked directly to the servo axes.
Hardware-based	There is a high-speed registration input for the encoder input and output axis.
Registration Inputs	On the rising or falling edge of a registration input, the MC Unit will store the
	current position in a register. The registered position can then be used by the
	BASIC program as required. The registered positions are captured in hard-
	ware.
General-purpose Input	Starting, stopping, limit switching, origin searches and many other functions
and Output Signals	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 trapezoidal speed profile is provided to generate smooth start-
	ing and stopping. The trapezoidal corners can be rounded off to S-curves.

Trapezoidal Speed Profile with	Trapezoidal Speed Profile with
Square Corners	S-curve Corners
Speed	Speed

Time

Time

4

System Configuration

Section 1-2

1-2	System Configuration
Basic Configuration
W-series Servo Driver		MCW151		Personal Computer running Motion Perfect
	M CW15 1			Personal
				Computer
	SD	RD
	RUN	ST S
		PORT0 ,1
		PORT2	1	Typical applicable Units for Serial Comm. Ports
	1	2
				PC
		I/ O
			2
	25	2 6		Programmable
		+ 24 V
		0V		Terminal (PT)
				General-purpose
				device

Typical applicable Actuators for Digital Outputs

Typical applicable Sensors for Servo

Relais

Driver Digital Inputs

Print Registration

Lamp

Limit Switches

Typical applicable Sensors for Digital Inputs

Power Supply connection

Print Registration

24 V Power supply Proximity Sensor

Typical applicable Pulse Generators for

Encoder Input

Typical applicable Units for Encoder Output

MCW151 Unit

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 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	R88M-W
	Control Devices (using	Programmable Terminals
	Host Link)	CPU Units
	Personal Computer (for	IBM Personal Computer or 100% compatible
	Motion Perfect)
	Motion Perfect	Version 2.0 or later
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	A DeviceNet system can be constructed in two ways: fixed allocation or free
(MCW151-DRT-E only)	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. More-
	over, with fixed allocation only one Master Unit can be used 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 Allocation

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 companies’ 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			Master Unit
	CPU Unit							Configurator
								ISA Board
					Message
	Remote I/O communications				communications
	MC Unit		Slave
					Slave		MC Unit

The following OMRON Master Units can be used.

Applicable PC	Master Unit model	Mounting position	Max. number of Units
	number
			With	Without
			Configurator	Configurator
CS1 Series	CS1-DRM21	CPU Rack or Expansion I/O Rack	16	1
		(Classified as Special I/O Units)
C200HZ/HX/HG/HE	C200HW-DRM21-V1	CPU Rack or Expansion I/O Rack	10 or 16 (see	1
		(Classified as Special I/O Units)	note)

Note Some CPUs can control 16 Master Units and other CPUs can control 10.

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 System	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 con-
	nected Servo Driver or the connected encoder into an internal absolute
	coordinate system.

The engineering unit which specifies 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 determined using the DEFPOS command. This command re-defines 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 MOVEABS) linear moves.

	MOVEABS(30)
	MOVE(60)
	MOVEABS(50)
	MOVE(50)
	MOVE(30)
0	50	100	Axis position

1-3-1 PTP-control

In point-to-point positioning, each axis is moved independently of the other axis. The MC Unit supports the following operations.

•Relative move

•Absolute move

•Continuous move forward

•Continuous move reverse

Relative and Absolute Moves

To move a single axis either the 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 same for both axes and the acceleration and deceleration rate are set sufficiently high, the movements for axis 0 and axis 1 will be as illustrated below.

Axis 1

MOVEABS(100) AXIS(0)

50

MOVEABS(50) AXIS(1)

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 conversion factor
ACCEL	Acceleration rate of an axis in units/s2
DECEL	Deceleration rate of an axis in units/s2
SPEED	Demand speed of an axis in units/s

8

Motion Control Concepts	Section 1-3
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 maxi-
	mum speed has been set to 10 m/s. In order to reach this speed in one
	second and also to decelerate to zero speed again in one second, both the
	acceleration as the deceleration rate have been set to 10 m/s2. The total dis-
	tance travelled is the sum of distances travelled during the acceleration, con-
	stant speed and deceleration segments. Suppose the distance moved by the
	MOVE command is 40 m, the speed profile will be given by the following
	graph.

Speed

ACCEL=10

10

DECEL=10

SPEED=10

MOVE(40)

0
	1		2				3				4			5				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

10

DECEL=10

SPEED=10

MOVE(40)

0
	1																	2			3				4			5			6				Time
Speed
																																			ACCEL=10
10																																			DECEL=5
																																			SPEED=10
																																			MOVE(40)

	0	1	2	3	4	5	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 D, the
	demand speed as V , the acceleration rate a and deceleration rate d .

9

Motion Control Concepts

Section 1-3

Continuous Moves

1-3-2 CP-control

Linear Interpolation

Acceleration time

Acceleration distance

Deceleration time

Deceleration distance

Constant speed distance

Total time

V

= -- a

V2

= -----

2a

V

= -- d

V2

= -----

2d

V2 ( a + d)

= D – -----------------------

2ad

DV( a + d)

=--- + --------------------

V 2ad

The FORWARD and REVERSE commands can be used to start a continuous movement with constant speed on a certain axis. The FORWARD command will move the axis in positive direction and the REVERSE command 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 move for one axis and RAPIDSTOP will cancel moves on all axes. The deceleration rate is set by DECEL.

Continuous Path control enables to control a specified path between the start 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 interpolation. In this case the commands will have 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

Speed

Axis 1

Time

Axis 0

10

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.

MOVECIRC(-100,0,-50,0,0)

Axis 1

50

				Axis 0
	-50	0	50

The centre point and desired end 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 interpolated MOVE command, the ACCEL, DECEL and SPEED variables associated with the base axis determine the speed profile along the circular move.

CAM Control

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)

Position

Time

1-3-3 EG-Control

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

Linked CAM control

Linked Move

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 CONNECT command in the program. In the command the ratio and the axis to link to are specified.

CONNECT Axis

2:1

1:1

1:2

Master Axis

Axes	Ratio	CONNECT command
0	1
	1:1	CONNECT(1,0) AXIS(1)
	2:1	CONNECT(2,0) AXIS(1)
	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 determined by the axis parameters of the axis but by the position of the linked axis. This is like connecting two axes through a cam.

CAMBOX(0,99,100,20,0) AXIS(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, deceleration 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 Axis (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 axis will consists of all movements of the actual axis plus the additional movements of the master axis.

BASE(0)

Speed axis 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 com-
	mands are given, the selected axis respectively all axes will cancel their cur-
	rent move.
Origin Search	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 command is used to set up a procedure whereby the MC Unit

goes through a sequence and searches 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 the position of an axis in a register when an event
	occurs. The event is referred to as the print registration input. On the rising 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 over-
	head and no interrupt service routines, eliminating the need to deal with the
	associated timing issues.
Merging Moves	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 inputs. Different speeds are also selectable by input.
	Refer to the FWD_JOG, REV_JOG and FAST_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 for 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 actual machine movements by the rotation of the motor in relation to a target 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
	MC Unit		Servo System
		2
			3
Demand		1	Speed
position	+		reference
		Position	Speed	Motor
		Control	Control
		-
				4
			Measured
			speed
				Encoder
		Measured
		position

Internal Operation of the Inferred closed loop systems occupy the mainstream in modern servo sys- MC Unit tems applied to positioning devices for industrial applications. The following graph shows the basic principle of the Servo System as used in the MC Unit.

1,2,3... 1. The MC Unit performs actual position control. The main input of the controller 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 demanded 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 will 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 motor by continuously adjusting the speed reference 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 the demand position, the measured position and the following error to determine the speed reference. The following error is the difference between the demanded and measured position. The demand position, measured 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