Omron SYSMAC C500-NC222-E Operation Manual

OPERATION MANUAL

Two-axis Position Control Unit
(NC221 Mode)

SYSMAC
C500-NC222-E

Cat. No. W138-E1-03

C500-NC222-E
Two-axis Position Control Unit
(NC221 Mode)

Operation Manual

Revised June 2003

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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 warnings in this manual. Always heed the
information provided with them.

DANGER Indicates information that, if not heeded, could result in loss of life or serious inju-

ry.

Caution Indicates information that, if not heeded, could result in minor injury or damage

to the product.

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, means
“word” and is abbreviated “Wd” in documentation.

Visual Aids

The following headings appear in the left column of the manual to help you locate different types of
information.

Indicates information of particular interest for efficient and convenient opera­tion of the product.

Indicates lists of one sort or another, such as procedures, precautions, etc.

 OMRON, 1990

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.

Note

1, 2, 3...

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TABLE OF CONTENTS

vii

PRECAUTIONS xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Intended Audience xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 General Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Safety Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Operating Environment Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Application Precautions xiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 Features 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 Basic Operating Principles 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3 Operational Flow 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4 System Configuration 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5 Control System Configuration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6 Control System Principles 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7 Precautions When Using C500-NC222-E in NC221 Mode 10. . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2

Wiring 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 M/D Connector 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 EXT-IN Connector 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3 Faulty Wiring Diagnostic Function 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 Motor Driver Connection Examples 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5 Wiring Precautions 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3

Data Configuration 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 Overview 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 Data Allocations 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 Setting Parameters 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 Setting Positioning Actions 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5 Setting Dwell Times 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6 Setting Acceleration and Deceleration Times 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7 Setting Speeds 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8 Initial Data 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4

Data Communication with PC 57. . . . . . . . . . . . . . . . . . . . .

4-1 Compatible Models and Words 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 PC Programs 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5

Operating Status 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 Flag Transitions and Types 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 Status Word Allocations 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 Status Word Details 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4 Flag Changes 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

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SECTION 6

Commands 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 Command Format 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 Command Descriptions 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 Command Processing 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4 Interpolation 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5 Relation between SRT and Positioning Actions 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7

Establishing the Origin 97. . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 CCHG 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2 Origin Search (XORG, YORG, IORG) 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 Origin Compensation 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8

Programming Examples 101. . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 Data Word Allocations 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 Data Transmission Program 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 Basic Program Examples 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4 Application Program Examples 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9

External Display, Switches, and Indicators 129. . . . . . . . . . .

9-1 External Display 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2 Display Descriptions 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3 Switches and Indicators 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10

Error Processing 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1 Procedure 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2 Basic Troubleshooting 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3 System Errors 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4 Command/Data Errors 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-5 Communications Errors 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix

A.Position Control Unit Specifications 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. External Display Specifications 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. Error Code List 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.Position Action Data Coding Sheets 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Revision History 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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About this Manual:

The C500-NC222-E Position Control Unit in NC221 mode is a Special I/O Unit for SYSMAC C500,
C1000H, and C2000H Programmable Controllers (PCs) that support WRIT (87) and READ (88). This
Position Control Unit (PCU) in NC221 mode is designed to control positioning through voltage outputs
to a motor driver according to PC programming and external control inputs.

This manual covers the specifications and procedures necessary for installation and operation. It also
describes data layouts and examples for communication between the PLC and NC222 Module in
NC221 mode. Before attempting to operate the Position Control Unit, be sure to thoroughly familiarize
yourself with the information contained in this manual. During operation, refer also to your PC Opera­tion Manual for programming and system details. If you wish to enter data manually via the Teaching
Box, please use this manual for wiring and setup only. Refer to manual number W145 for data entry
and operations.

Section 1 contains information on the features of the Position Control Unit, system configuration, and
an overview of control system principles.

Section 2 contains wiring diagrams and other information necessary for installation and connection of
the Position Control Unit.

Section 3 provides the minimum information necessary to assemble and test a servomotor driver
system using both axes.

Sections 4, 5, and 6 provide information essential for operation, including data configuration, the set­ting of parameters and positioning actions, communication between the Position Control Unit and the
PC, and the use of status flags.

Section 7 provides a description of command format. It also contains tables of system, servo control,
and data processing commands, including the functions and usage examples for each.

Section 8 shows how to establish the origin, which must be done to establish a reference point be­fore executing positioning actions.

Section 9 provides a variety of programming examples to illustrate the principles covered in this man­ual.

Sections 10 and 11 cover external displays and error processing.

The appendices contain specifications, an error code list, and data coding sheets.

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.

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PRECAUTIONS

This section provides general precautions for using the Programmable Controller (PC) and related devices.

The information contained in this section is important for the safe and reliable application of the PC. You must read
this section and understand the information contained before attempting to set up or operate a PC system.

1 Intended Audience xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 General Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Safety Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Operating Environment Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Application Precautions xiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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.

Before using the product under conditions which are not described in the manual
or applying the product to nuclear control systems, railroad systems, aviation
systems, vehicles, combustion systems, medical equipment, amusement
machines, safety equipment, and other systems, machines, and equipment that
may have a serious influence on lives and property if used improperly, consult
your OMRON representative.

Make sure that the ratings and performance characteristics of the product are
sufficient for the systems, machines, and equipment, and be sure to provide the
systems, machines, and equipment with double safety mechanisms.

This manual provides information for programming and operating OMRON PCs.
Be sure to read this manual before attempting to use the software and keep this
manual close at hand for reference during operation.

WARNING It is extreme important that a PC and all PC Units be used for the specified

purpose and under the specified conditions, especially in applications that can
directly or indirectly affect human life. You must consult with your OMRON
representative before applying a PC System to the abovementioned
applications.

3 Safety Precautions

WARNING Never attempt to disassemble any Units while power is being supplied. Doing so

may result in serious electrical shock or electrocution.

WARNING Never touch any of the terminals while power is being supplied. Doing so may

result in serious electrical shock or electrocution.

4 Operating Environment Precautions

Do not operate the control system in the following places.

• Where the PC is exposed to direct sunlight.

• Where the ambient temperature is below 0°C or over 55°C.

• Where the PC may be affected by condensation due to radical temperature

changes.

• Where the ambient humidity is below 10% or over 90%.

• Where there is any corrosive or inflammable gas.

• Where there is excessive dust, saline air, or metal powder.

• Where the PC is affected by vibration or shock.

• Where any water, oil, or chemical may splash on the PC.

Operating Environment Precautions

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xiii

Caution The operating environment of the PC System can have a large effect on the lon-

gevity and reliability of the system. Improper operating environments can lead to
malfunction, failure, and other unforeseeable problems with the PC System. Be
sure that the operating environment is within the specified conditions at installa­tion and remains within the specified conditions during the life of the system.

5 Application Precautions

Observe the following precautions when using the PC.

WARNING Failure to abide by the following precautions could lead to serious or possibly

fatal injury. Always heed these precautions.

• Always ground the system to 100 Ω or less when installing the system to pro­tect against electrical shock.

• Always turn off the power supply to the PC before attempting any of the follow­ing. Performing any of the following with the power supply turned on may lead
to electrical shock:

• Mounting or removing any Units (e.g., I/O Units, CPU Unit, etc.) or memory
cassettes.

• Assembling any devices or racks.

• Connecting or disconnecting any cables or wiring.

Caution Failure to abide by the following precautions could lead to faulty operation or the

PC or the system or could damage the PC or PC Units. Always heed these pre­cautions.

• Use the Units only with the power supplies and voltages specified in the opera­tion manuals. Other power supplies and voltages may damage the Units.

• Take measures to stabilize the power supply to conform to the rated supply if it
is not stable.

• Provide circuit breakers and other safety measures to provide protection
against shorts in external wiring.

• Do not apply voltages exceeding the rated input voltage to Input Units. The
Input Units may be destroyed.

• Do not apply voltages exceeding the maximum switching capacity to Output
Units. The Output Units may be destroyed.

• Always disconnect the LG terminal when performing withstand voltage tests.

• Install all Units according to instructions in the operation manuals. Improper

installation may cause faulty operation.

• Provide proper shielding when installing in the following locations:

• 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 to power supply lines.

• Be sure to tighten Backplane screws, terminal screws, and cable connector

screws securely.

• Do not attempt to take any Units apart, to repair any Units, or to modify any
Units in any way.

Caution The following precautions are necessary to ensure the general safety of the sys-

tem. Always heed these precautions.

• Provide double safety mechanisms to handle incorrect signals that can be
generated by broken signal lines or momentary power interruptions.

• Provide external interlock circuits, limit circuits, and other safety circuits in
addition to any provided within the PC to ensure safety.

Application Precautions

5

1

SECTION 1

Introduction

The C500-NC222-E Position Control Unit (PCU) in NC221 mode is a Special I/O Unit that receives positioning commands
from the Programmable Controller (PC) and outputs control voltages to two servomotor drivers. Since it outputs control volt­ages rather than pulses, it can be directly connected to any of a variety of servomotor drivers. You can use it with the C500,
C1000H, or C2000H PC.

Each of the two servomotor drivers controls a servomotor which rotates one of the two positioning axes. The Position Control
Unit can control the axes independently or simultaneously. Both straight-line and circular arc interpolation are also possible.

This section describes the basic features, components, and operation of the Position Control Unit in NC221 mode, as well as
the basic configuration and principles of positioning control systems. Reading this section first will give you a familiarity with
the essential terminology used in this manual and an understanding of the fundamentals necessary for successful operation.

1-1 Features 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 Basic Operating Principles 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3 Operational Flow 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4 System Configuration 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5 Control System Configuration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6 Control System Principles 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7 Precautions When Using C500-NC222-E in NC221 Mode 10. . . . . . . . . . . . . . . . . . . . . . . . .

2

1-1 Features

A control output voltage range from –10 V to +10 V enables connection to
various servomotor drivers.

The Position Control Unit is designed to control two axes. Data configuration
consisting of parameters, speeds, dwell times, acceleration and deceleration
times, and positioning actions permits straight-line interpolation or circular arc
interpolation by simultaneous dual-axis operation. Each motor axis may also
be operated independently.

Troubleshooting is facilitated by error code transmission from the Position
Control Unit to the PC as well as by error code display on the External Dis­play.

The data capacity in the Position Control Unit provides 300 positioning ac­tions per axis, 19 parameters per axis, 100 speeds, 10 dwell times per axis,
and 10 acceleration and deceleration times per axis. All data is stored in the
built-in EEPROM for battery-free and maintenance-free backup. Data is read
into the RAM from the EEPROM when power is turned ON.

Connecting the Teaching Box permits position inputs, position input reading,
teaching inputs, and operation monitoring.

All data and command communications between the Programmable Control­ler and Position Control Unit use PC Intelligent I/O Read and Write instruc­tions permitting high-speed processing.

The C500-NC222-E Position Control Unit in NC221 mode can be used with a
C500, C1000H, or C2000H PC. The C500-CPU11-EV1 CPU can be used
with the C500, CVM1, CV500, CV1000, or CV2000 PC. Any C1000H and
C2000H CPU may be used.

1-2 Basic Operating Principles

The basic operation of the C500-NC222-E Position Control Unit is fairly sim­ple. It controls a servomotor driver in accordance with data stored in its
memory. This data includes parameters, speeds, positions, and other infor­mation necessary for effective control. Before the Position Control Unit can
be operated, you must first input the essential data. This is generally done
via the Teaching Box.

The way in which the Position Control Unit makes use of this data is deter­mined by the program in the PC. The program does not control all of the Po­sition Control Unit’s operations directly, but rather, transfers commands to the
Position Control Unit for execution. The commands control such functions as
the starting and stopping of positioning, returning to the origin, and so on.
Thus, while the Position Control Unit functions as an integral part of your
overall control system, it also exercises a good deal of autonomy. This capa­bility is essential to the concept of distributed control, whereby control of
each portion of an automated system is located near the devices actually
being controlled.

Applicable Motor Drivers

Number of Control Axes
and Controlling Capacity

Error Diagnostics

Large Data Capacity with
Backup

Teaching Box

High-speed
Communications Between
PC and PCU

Applicable CPUs

Basic Operating Principles

Section 1-2

3

The fundamental unit of positioning is the positioning action. A particular po­sitioning action moves the workpiece along the axis in a direction, at a speed,
and to a position determined by the data which has been set specifically for
the positioning action. The positioning action begins when the start command
is transferred by the PC program (XSRT, YSRT, or ISRT, depending on
whether you want to position along the X axis, the Y axis, or both simulta­neously). Before beginning execution of positioning actions, it is necessary to
define the origin as a reference point by, for example, executing origin search
(XORG, YORG, or IORG). The origin is simply the point which is designated
as 0 at any given time. Positioning actions are described in detail in 3-4 Set-
ting Positioning Actions, using commands to start positioning actions is de­scribed in 6-5 SRT (Start) Commands and Positioning Actions, and using
commands with the origin is described in Section 7 Establishing the Origin.

Basic Operating Principles

Section 1-2

4

1-3 Operational Flow

Positioning operations generally involve the following steps.

NO (no error)

Wiring between
servomotor drivers and
Position Control Unit

START

Wiring external
inputs

Wiring between motors
and servomotor drivers

Power ON

Operation via
PC program?

Write PC
program.

Run PC
program.

Confirm motor
operation.

Change to
actual data.

Change PC program
to actual program.

Run PC
program.

Confirm motor
operation.

Error LED

lights?

Read
error code.

Correct
error.

Error
cleared?

Connect
Teaching Box.

Operate
Teaching Box.

Confirm motor
operation.

Change to
actual data.

Operate
Teaching Box.

Yes

No

No (no error)

No

Yes

Trial
operation

Mount motors
to mechanical
system.

Final
wiring

Create PC
program application.

Yes (error)

Confirm actual

operation.

Refer to
appropriate
operation
manuals.

Error LED

lights?

Read error code.

Correct error.

Error cleared?

NO

YES

Operation

(positioning actions)

YES (error)

Original, CW limit CCW limit,
emergency stop, external interrupt, etc.
Refer to Section 2 Wiring.

Wire according to operation
manuals for motors and
servomotor drivers.

Refer to 2-4 Motor Driver Connection

Examples

Initial data is set. Servolock enabled.
Refer to 3-8 Initial Data.

Refer to the
operation
manual for
the Teaching
Box.

Refer to

Section 8
Programming
Examples.

Setup Debugging

Operational Flow

Section 1-3

5

1-4 System Configuration

The following configuration illustrates example connections for a working sys­tem.

Note The Position Control Unit cannot be used if mounted to a Slave Rack.

Control inputs

PC

C500-TU002-E
Teaching Box

Feedback inputs, control voltages

24-VDC
power supply

External interrupt
switch

Control
panel

External input
switches

External input switches

AC Servomotor

AC Servomotor Driver

AC Servomotor Driver

24-VDC
power supply

C500-NC222-E

AC Servomotor

Emergency
stop switch

0

System Configuration

Section 1-4

6

1-5 Control System Configuration

The following block diagram shows a control system for a servomotor driver.
The Position Control Unit is arranged in a semiclosed-loop system.

C500-NC222-E PCU

Control voltage
output
+10 V

Servomotor driver

Servomotor

Position

Tachogenerator

Position feedback

Rotary encoder

CW limit Origin CCW limit

Emergency stop External interrupt

Teaching Box

C500-TU002-E

Memory

D/A convertor

(16 bits)

Counter

Extrnal input

interface

Teaching Box–

External Display

interface

M/D (Motor Driver)

connector

Peripheral

connector

MPU

PC

PC bus interface

EXT–IN

connector

–10 V

Speed feedback

Control Inputs

1-6 Control System Principles

Control systems can be quite simple or relatively complex. The most basic is
an open-loop system, in which a particular operation is carried out, according
to programmed instructions, but in which no feedback is provided for auto­matic adjustments.

In a closed-loop system, PC controls an external process without human in­tervention. The servomotor provides direct feedback so that actual values (of
positions, speeds, and so on) are continuously adjusted to bring them more
closely in line with target values. The digital feedback signals are commonly
transmitted to a digital-to-analog converter to complete the feedback loop,
thereby permitting automated control of the process.

The C500-NC222-E Position Control Unit is designed for use in a semi­closed-loop system. A semiclosed-loop system is similar to a closed-loop
system, except that feedback is provided by a tachogenerator and a rotary
encoder rather than directly by the servomotor. This system, which also in-

Open-loop Systems

Closed-loop Systems

Semiclosed-Loop Systems

Control System Principles

Section 1-6

7

cludes an error counter, a D/A converter, and a servomotor driver, detects
machine movements by rotation of the motor in relation to the target, com­putes the error between the target value and actual movement, and zeroes
the error through feedback.

Servo­motor
driver

Tachogenerator

Rotary encoder

Speed feedback

Position feedback (feedback pulses)

Speed
voltage

D/A
converter

Desired position

Error
counter

Servomotor

(pulse string)

1. First, the error counter receives a target position in units of encoder

pulses. The error counter transfers its contents to the D/A convertor
which converts the contents to analog speed voltages for the servomo­tor driver.

Servomotor Driver
Speed Characteristics

Rotational speed
+N (rpm)

–V

+V Speed voltage

–N

Position Control Unit
Action

Control System Principles

Section 1-6

8

2. The motor rotates at a speed corresponding to the speed voltage. The

rotary encoder connected to the motor axis rotates in sync with the mo­tor, generates feedback pulses, and subtracts error counter contents.

Desired
position
(pulses)

Error
counter
count
(pulses)

Speed
voltage

Time set

Positioning end

Time

Time

Time

3. Consequently, the encoder rotation is equivalent to the target position,

and the motor stops rotating when the error counter count and the
speed voltage becomes zero (stopping motor rotation).

4. While the motor is stopped, the rotary encoder constantly maintains the

stopped position through correction. If the motor axis moves slightly, the
error counter receives a feedback pulse from the rotary encoder and a
rotation voltage is emitted in the reverse direction, causing the motor to
rotate toward its original position. This operation is called servolock or
servoclamp.

Control System Principles

Section 1-6

9

5. In order to execute positioning by the semiclosed-loop method with ac-

celeration and deceleration, target positions are set consecutively in the
error counter for processing, thus enabling smooth acceleration and de­celeration.

Desired
position
(pulses)

Error
counter
count
(pulses)

Speed
voltage

Time

Time

Time

6. The target position becomes the count for the error counter and controls

the motor by conversion to a speed voltage for the servomotor driver.
Thus, the position equals the total count of target positions (shaded area
in the figure), and the speed will depend on the desired position per unit
time.

Consider the following positioning system where millimeter is selected as the
unit:

N

V

P

L

M

Rotary encoder

Servomotor

Reduction gear

Moving object

Feed-screw pitch

Where:
N = rotary encoder resolution (pulse/rev)
M = reduction ratio
V = speed of moving object (mm/s)
P = feed-screw pitch (mm/rev)
L = distance moved (mm)

Simplified Positioning
System Design

Control System Principles

Section 1-6

10

Here,

Positioning precision =

Feed-screw pitch
Encoder pulses x reduction ratio

=

P (mm/rev)
N (pulse/rev) x M

=

P
N x M

(mm/pulse)

The positioning precision is called the pulse rate. Next, the required pulse
speed from the encoder is:

Required pulse speed =

Feeding speed
Pulse rate

V (mm/s)
Pulse rate (mm/pulse)

=

=

V x N x M
P

(pulses)

For a movement of L mm:

Requisite no. of pulses =

Distance moved
Pulse rate

=

L / P
N x M

=

N x M x L
P

(pulses)

1-7 Precautions When Using C500-NC222-E in NC221 Mode

The C500-NC222-E in NC221 mode is different from the C500-NC221-E in
the following points.

1, 2, 3... 1. Internal Control Cycle

The internal control cycle of the C500-NC222-E in NC221 mode is different
from that of the C500-NC221-E. Accordingly, the output distribution cycle
and external input read timing of the C500-NC222-E in NC221 mode are dif­ferent from those of the C500-NC221-E.

Control Cycle

The control cycle is the time required
for an NC output change (i.e., a
speed instruction voltage change)
plus the time required for input read.

Control cycle

Control Cycle:

C500-NC221-E: 3.2 ms

C500-NC222-E in NC221 mode:4.0 ms

2. Difference in Operation Due to Changes in Internal Control Cycle

Due to the difference of the internal control cycle of the C500-NC222-E in
NC221 mode and that of the C500-NC221-E, the tact time (i.e., the time
required for the whole positioning operation) of the C500-NC221-E is some­times different from that required by the C500-NC222-E in NC221 mode.

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

11

There will be no timing errors if the C500-NC222-E in NC221 mode and the
C500-NC221-E are in correct timing control operation, which however, does
not mean that there is no difference in tact time between the C500-NC221-E
and the C500-NC222-E in NC221 mode.

Change in Tact Time

A

There is no difference in movement range between the C500-NC222-E in
NC221 mode and the C500-NC221-E. The period A, which is the value left
over by the internal operation of the C500-NC222-E in NC221 mode as
shown in the above timing chart on the right hand side, however, may be
produced. The difference in tact time is caused by the period A, which can
be, however, solved by adjusting the speed data or movement range of the
C500-NC222-E.

3. Parameter Settings Before Shipping

The parameters of the C500-NC222-E are factory-set so that the
C500-NC222-E can be used in NC222 mode. NC221 and NC222 mode
parameters share the same area of the C500-NC222-E. Therefore, before
using the C500-NC222-E in NC221 mode, be sure to change the parame­ters. Refer to the following table for the differences between NC221 and
NC222 mode parameters.

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

12

Address Type Initial data and data attributes

NC221 NC221 mode NC222

X-axis test
data

100 X-axis test

data 1

Position data: 500
pulses; speed data: 1; M
code: 01; dwell timer: 5;
ABS; Pattern: 0; accel­eration and deceleration
pattern: 5

Position data: 1,000
pulses; speed data: 1; M
code: 01; dwell timer: 5;
ABS; Pattern: 0; accel­eration and deceleration
pattern: 5

Position data: 1,000
pulses; speed data: 1; M
code: 01; dwell timer: 5;
ABS; Pattern: 0; accel­eration and deceleration
pattern: 5

101 X-axis test

data 2

Position data: –500
pulses; speed data: 3; M
code: 02; dwell timer: 0;
INC; Pattern: 1; accel­eration and deceleration
pattern: 0

Position data: –1,000
pulses; speed data: 3; M
code: 02; dwell timer: 0;
INC; Pattern: 1; accel­eration and deceleration
pattern: 0

Position data: 1,000
pulses; speed data: 3; M
code: 02; dwell timer: 0;
INC; Pattern: 1; accel­eration and deceleration
pattern: 0

102 Position data: –500

pulses; speed data: 2; M
code: 03; dwell timer: 5;
ABS; Pattern: 1; accel­eration and deceleration
pattern: 2

Position data: –1,000
pulses; speed data: 2; M
code: 03; dwell timer: 5;
ABS; Pattern: 1; accel­eration and deceleration
pattern: 2

Position data: 1,000
pulses; speed data: 2; M
code: 03; dwell timer: 5;
ABS; Pattern: 1; accel­eration and deceleration
pattern: 2

103 Position data: –500

pulses; speed data: 1; M
code: 04; dwell timer: 1;
INC; Pattern: 0; accel­eration and deceleration
pattern: 1

Position data: –1,000
pulses; speed data: 1; M
code: 04; dwell timer: 1;
INC; Pattern: 0; accel­eration and deceleration
pattern: 1

Position data: 1,000
pulses; speed data: 1; M
code: 04; dwell timer: 1;
INC; Pattern: 0; accel­eration and deceleration
pattern: 1

104 X/Y-axis test

data 1

Position data: 0 pulses;
speed data: 1; M code:
05; dwell timer: 1; ABS;
acceleration and decel­eration pattern: 1; inter­polation end point

Position data: 0 pulses;
speed data: 1; M code:
05; dwell timer: 1; ABS;
acceleration and decel­eration pattern: 1; inter­polation end point

Position data: 0 pulses;
speed data: 1; M code:
05; dwell timer: 1; ABS;
acceleration and decel­eration pattern: 1; inter­polation end point

X-axis 400 Unit setting 0 0 0

parameter 401 Pulse rate 1 1 1

data 402 Rotating

direction

0 0 0

403 Encoder

type

01 01 001

404 Gain 200 200 200

405 In-position

zone

10 10 10

406 Backlash

compensa­tion

0 0 0

407 Stroke limit

(+)

999999 999999 999999

408 Stroke limit

(–)

999999 999999 999999

409 Zone setting 01000100 01000100 01000100

410 Home shift 0 0 0

411 Maximum

speed

10000 FFFFFFFF (*1: see

note)

40010000

412 Jog forward

maximum
speed

2000 FFFFFFFF (*2: see

note)

10002000

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

13

Initial data and data attributesTypeAddress

NC222NC221 modeNC221

X-axis
parameter
data

413 Origin

search direc­tion

0 0 0

414 Origin com-

pensation

0 0 0

415 Origin

search maxi­mum speed

5000 5000 5000

416 Origin

search
acceleration
and decel­eration

5 5 5

417 Origin

search low
speed

1000 1000 1000

418 Deceleration

stop pulse
number

500 500 00000500

419 Wiring check

function

--- --- 01100011

Emergency
stop counter
capacity

0 7024 ---

420 External out-

put control
setting

00032768 00032768 00032768

Dwell timer 450/850 Dwell timer 0 0 –1 0

451/851 Dwell timer 1 100 –1 100

452/852 Dwell timer 2 200 –1 200

453/853 Dwell timer 3 300 0 300

454/854 Dwell timer 4 400 100 400

455/855 Dwell timer 5 500 200 500

456/856 Dwell timer 6 600 0 600

457/857 Dwell timer 7 700 100 700

458/858 Dwell timer 8 800 200 800

459/859 Dwell timer 9 900 300 900

Acceleration
and decel­eration pat­tern

460/860 Acceleration

and decel­eration pat­tern 0

00100010 00000400 00100010

461/861 Acceleration

and decel­eration pat­tern 1

00100020 00000500 00100020

462/862 Acceleration

and decel­eration pat­tern 2

00100030 00000600 00100030

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

14

Initial data and data attributesTypeAddress

NC222NC221 modeNC221

Acceleration
and decel­eration pat­tern

463/863 Acceleration

and decel­eration pat­tern 3

00100040 00000700 00100040

464/864 Acceleration

and decel­eration pat­tern 4

00100050 00000800 00100050

465/865 Acceleration

and decel­eration pat­tern 5

00200020 00000900 00200020

466/866 Acceleration

and decel­eration pat­tern 6

00200030 00100010 00200030

467/867 Acceleration

and decel­eration pat­tern 7

00200040 00100020 00200040

468/868 Acceleration

and decel­eration pat­tern 8

00200050 00100030 00200050

469/869 Acceleration

and decel­eration pat­tern 9

00200060 00100040 00200060

Y-axis test
data

500 Y-axis test

data 1

Position data: 500
pulses; speed data: 1; M
code: 06; dwell timer: 5;
INC; Pattern: 0; accel­eration and deceleration
pattern: 5

Position data: 1,000
pulses; speed data: 1; M
code: 06; dwell timer: 5;
INC; Pattern: 0; accel­eration and deceleration
pattern: 5

Position data: 10,000
pulses; speed data: 1; M
code: 06; dwell timer: 5;
INC; Pattern: 0; accel­eration and deceleration
pattern: 5

501 Y-axis test

data 2

Position data: 0 pulses;
speed data: 1; M code:
07; dwell timer: 0; ABS;
Pattern: 1; acceleration
and deceleration pat­tern: 0

Position data: 0 pulses;
speed data: 3; M code:
07; dwell timer: 0; ABS;
Pattern: 1; acceleration
and deceleration pat­tern: 0

Position data: 0 pulses;
speed data: 3; M code:
07; dwell timer: 0; ABS;
Pattern: 1; acceleration
and deceleration pat­tern: 0

502 Position data: –500

pulses; speed data: 2; M
code: 08; dwell timer: 5;
INC; Pattern: 1; accel­eration and deceleration
pattern: 2

Position data: –1,000
pulses; speed data: 2; M
code: 08; dwell timer: 5;
INC; Pattern: 1; accel­eration and deceleration
pattern: 2

Position data: 1,000
pulses; speed data: 2; M
code: 08; dwell timer: 5;
INC; Pattern: 1; accel­eration and deceleration
pattern: 2

503 Position data: –1,000

pulses; speed data: 3; M
code: 09; dwell timer: 0;
ABS; Pattern: 0; accel­eration and deceleration
pattern: 1

Position data: –1,000
pulses; speed data: 1; M
code: 09; dwell timer: 0;
ABS; Pattern: 0; accel­eration and deceleration
pattern: 1

Position data: –2,000
pulses; speed data: 1; M
code: 09; dwell timer: 0;
ABS; Pattern: 0; accel­eration and deceleration
pattern: 1

504 X/Y-axis test

data 1

Position data: 0 pulses;
speed data: 1; M code:
10; dwell timer: 1; ABS;
acceleration and decel­eration pattern: 1; inter­polation end point

Position data: 0 pulses;
speed data: 1; M code:
10; dwell timer: 1; ABS;
acceleration and decel­eration pattern: 1; inter­polation end point

Position data: 0 pulses;
speed data: 1; M code:
10; dwell timer: 1; ABS;
acceleration and decel­eration pattern: 1; inter­polation end point

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

15

Initial data and data attributesTypeAddress

NC222NC221 modeNC221

Y-axis 800 Unit setting 0 0 0

parameter 801 Pulse rate 1 1 1

data 802 Rotating

direction

0 0 0

803 Encoder

type

01 01 001

804 Gain 200 200 200

805 In-position

zone

10 10 10

806 Backlash

compensa­tion

0 0 0

807 Stroke limit

(+)

999999 999999 999999

808 Stroke limit

(–)

999999 999999 999999

809 Zone setting 01000100 01000100 01000100

810 Home shift 0 0 0

811 Maximum

speed

10000 FFFFFFFF (*1: see

note)

40010000

812 Jog forward

maximum
speed

2000 FFFFFFFF (*2: see

note)

10002000

813 Origin

search direc­tion

0 0 0

814 Origin com-

pensation

0 0 0

815 Origin

search maxi­mum speed

5000 5000 5000

816 Origin

search
acceleration
and decel­eration

5 5 5

817 Origin

search low
speed

1000 1000 1000

818 Deceleration

stop pulse
number

500 500 00000500

819 Wiring check

function

--- --- 01100011

Emergency
stop counter
capacity

0 7024 ---

820 External out-

put control
setting

00032768 00032768 00032768

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

16

Initial data and data attributesTypeAddress

NC222NC221 modeNC221

Speed data 900 Speed data010000 10000 10000

901 Speed data11000 1000 1000

902 Speed data22000 2000 2000

903 Speed data33000 3000 3000

904 Speed data44000 4000 4000

905 Speed data55000 5000 5000

906 Speed data66000 6000 6000

907 Speed data77000 7000 7000

908 Speed data88000 8000 8000

909 Speed data99000 9000 9000

Note The Teaching Unit displays the following in the above *1) and *2) cases.

*1: OVER_PS
*2: JOG OVER_PS

Precautions When Using C500-NC222-E in NC221 Mode

Section 1-7

17

SECTION 2

Wiring

2-1 M/D Connector 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 EXT-IN Connector 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3 Faulty Wiring Diagnostic Function 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 Motor Driver Connection Examples 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5 Wiring Precautions 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

2-1 M/D Connector

The M/D (motor driver) connector is used for wiring servomotor driver I/O.
Control voltage outputs and feedback pulse inputs go through here. The con­nector type and pin layouts are shown below.

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16

17 18 19 20 21 22 23 24

25

2.6x6=15.6

2.6x8=20.8

6.1

2.6

2.6

33

(Layout shown from wiring side)

M/D Connector Section 2-1

19

Pin Terminal Functions

Name

0 V

X-axis OUT2 output

X-axis OUT1 output

X-axis Phase B input

X-axis Phase B input

X-axis Phase A input

X-axis Phase A input

X-axis speed 0 V

X-axis speed

Frame ground

24 V for OUT output

Y-axis phase Z input

X-axis phase Z input

X-axis phase Z input

Y-axis phase Z input

0 V

Y-axis OUT2 output

Y-axis OUT1 output

Y-axis Phase B input

Y-axis Phase B input

Y-axis Phase A input

Y-axis Phase A input

Y-axis speed 0 V

Y-axis speed instruction

Description

0-V terminal for pins 11 and 12

User defined output (for X axis)

Phase B feedback input for X axis

Phase B feedback input for X axis

Phase A feedback input for X axis

Phase A feedback input for X axis

0-V output for X-axis speed voltage to servomotor
driver

X-axis speed voltage output to servomotor driver

Ground terminal

+24 VDC input terminal for OUT output

Phase Z feedback input for Y axis

Phase Z feedback input for Y axis

Phase Z feedback input for X axis

Phase Z feedback input for X axis

0-V terminal for pins 18 and 19

User defined output (for Y axis)

Phase B feedback input for Y axis

Phase B feedback input for Y axis

Phase A feedback input for Y axis

Phase A feedback input for Y axis

0-V output for Y-axis speed voltage to servomotor
driver

Y-axis speed voltage output to servomotor driver

Pin No. Symbol

1 DC GND

2 OUT-2X

3 OUT-1X

4 X-B

5 X-B

6 X-A

7 X-A

8 XAG

9 XOUT

10 FG

11 +24V

12 +24V

13 Y-Z

14 Y-Z

15 X-Z

16 X-Z

17 DC GND

18 OUT 2Y

19 OUT 1Y

20 Y-B

21 Y-B

22 Y-A

23 Y-A

24 YAG

25 YOUT

M/D Connector Section 2-1