Mitsubishi Electric RD77MS2 User manual

MELSEC iQ-R Simple Motion Module
User's Manual (Advanced Synchronous Control)
RD77MS2
RD77MS4
RD77MS8
RD77MS16

1
SAFETY PRECAUTIONS
(Read these precautions before using this product.)
Before using this product, please read this manual and the relevant manuals carefully and pay full attention to safety to handle
the product correctly. The precautions given in this manual are concerned with this product only. Refer to the user’s manual of
the CPU module to use for a description of the PLC system safety precautions.
In this manual, the safety precautions are classified into two levels: " WARNING" and " CAUTION".
Under some circumstances, failure to observe the precautions given under " CAUTION" may lead to serious
consequences.
Observe the precautions of both levels because they are important for personal and system safety.
Make sure that the end users read this manual and then keep the manual in a safe place for future reference.
[Design Precautions]
WARNING
●Configure safety circuits external to the programmable controller to ensure that the entire system
operates safely even when a fault occurs in the external power supply or the programmable controller.
Failure to do so may result in an accident due to an incorrect output or malfunction.
(1) Configure external safety circuits, such as an emergency stop circuit, protection circuit, and
protective interlock circuit for forward/reverse operation or upper/lower limit positioning.
(2) The programmable controller stops its operation upon detection of the following status, and the
output status of the system will be as shown below.
• Turned off if the overcurrent or overvoltage protection of the power supply module is activated.
• Held or turned off according to the parameter setting if the self-diagnostic function of the CPU
module detects an error such as a watchdog timer error.
(3) Also, all outputs may be turned on if an error occurs in a part, such as an I/O control part, where
the CPU module cannot detect any error. To ensure safety operation in such a case, provide a
safety mechanism or a fail-safe circuit external to the programmable controller. For a fail-safe
circuit example, refer to the user's manual of the CPU module to use.
(4) Outputs may remain on or off due to a failure of a component such as a relay and transistor in an
output circuit. Configure an external circuit for monitoring output signals that could cause a
serious accident.
●In an output circuit, when a load current exceeding the rated current or an overcurrent caused by a
load short-circuit flows for a long time, it may cause smoke and fire. To prevent this, configure an
external safety circuit, such as a fuse.
●Configure a circuit so that the programmable controller is turned on first and then the external power
supply. If the external power supply is turned on first, an accident may occur due to an incorrect output
or malfunction.
●For the operating status of each station after a communication failure, refer to manuals relevant to the
network. Incorrect output or malfunction due to a communication failure may result in an accident.
WARNING Indicates that incorrect handling may cause hazardous conditions, resulting in
death or severe injury.
CAUTION Indicates that incorrect handling may cause hazardous conditions, resulting in
minor or moderate injury or property damage.

2
●When connecting an external device with a CPU module or intelligent function module to modify data
of a running programmable controller, configure an interlock circuit in the program to ensure that the
entire system will always operate safely. For other forms of control (such as program modification,
parameter change, forced output, or operating status change) of a running programmable controller,
read the relevant manuals carefully and ensure that the operation is safe before proceeding. Improper
operation may damage machines or cause accidents.
●Especially, when a remote programmable controller is controlled by an external device, immediate
action cannot be taken if a problem occurs in the programmable controller due to a communication
failure. To prevent this, configure an interlock circuit in the program, and determine corrective actions
to be taken between the external device and CPU module in case of a communication failure.
●Do not write any data to the "system area" and "write-protect area" of the buffer memory in the
module. Also, do not use any "use prohibited" signals as an output signal from the CPU module to
each module. Doing so may cause malfunction of the programmable controller system. For the
"system area", "write-protect area", and the "use prohibited" signals, refer to the user's manual for the
module used.
●If a communication cable is disconnected, the network may be unstable, resulting in a communication
failure of multiple stations. Configure an interlock circuit in the program to ensure that the entire
system will always operate safely even if communications fail. Failure to do so may result in an
accident due to an incorrect output or malfunction.
●To maintain the safety of the programmable controller system against unauthorized access from
external devices via the network, take appropriate measures. To maintain the safety against
unauthorized access via the Internet, take measures such as installing a firewall.
●Configure safety circuits external to the programmable controller to ensure that the entire system
operates safely even when a fault occurs in the external power supply or the programmable controller.
Failure to do so may result in an accident due to an incorrect output or malfunction.
(1) Machine home position return is controlled by two kinds of data: a home position return direction
and a home position return speed. Deceleration starts when the near-point dog signal turns on. If
an incorrect home position return direction is set, motion control may continue without
deceleration. To prevent machine damage caused by this, configure an interlock circuit external to
the programmable controller.
(2) When the module detects an error, the motion slows down and stops or the motion suddenly
stops, depending on the stop group setting in parameter. Set the parameter to meet the
specifications of a positioning control system. In addition, set the home position return parameter
and positioning data within the specified setting range.
(3) Outputs may remain on or off, or become undefined due to a failure of a component such as an
insulation element and transistor in an output circuit, where the module cannot detect any error. In
a system that the incorrect output could cause a serious accident, configure an external circuit for
monitoring output signals.
●If safety standards (ex., robot safety rules, etc.,) apply to the system using the module, servo amplifier
and servomotor, make sure that the safety standards are satisfied.
●Construct a safety circuit externally of the module or servo amplifier if the abnormal operation of the
module or servo amplifier differs from the safety directive operation in the system.
●Do not remove the SSCNETcable while turning on the control circuit power supply of Multiple CPU
system and servo amplifier. Do not see directly the light generated from SSCNETconnector of the
module or servo amplifier and the end of SSCNETcable. When the light gets into eyes, you may
feel something wrong with eyes. (The light source of SSCNETcomplies with class1 defined in
JISC6802 or IEC60825-1.)
WARNING

3
[Design Precautions]
CAUTION
●Do not install the control lines or communication cables together with the main circuit lines or power
cables. Keep a distance of 100 mm or more between them. Failure to do so may result in malfunction
due to noise.
●During control of an inductive load such as a lamp, heater, or solenoid valve, a large current
(approximately ten times greater than normal) may flow when the output is turned from off to on.
Therefore, use a module that has a sufficient current rating.
●After the CPU module is powered on or is reset, the time taken to enter the RUN status varies
depending on the system configuration, parameter settings, and/or program size. Design circuits so
that the entire system will always operate safely, regardless of the time.
●Do not power off the programmable controller or do not reset the CPU module during the setting
registration. Doing so will make the data in the flash ROM undefined. The data need to be set in the
buffer memory and to be written to the flash ROM again. Doing so may cause malfunction or failure of
the module.
●Reset the CPU module after changing the parameters. Failure to do so may cause malfunction
because the previous parameter settings remain in the module.
●When changing the operating status of the CPU module from external devices (such as remote RUN/
STOP), select "Do Not Open by Program" for "Opening Method" in the module parameters. If "Open
by Program" is selected, an execution of remote STOP causes the communication line to close.
Consequently, the CPU module cannot reopen the communication line, and external devices cannot
execute the remote RUN.

4
[Installation Precautions]
[Installation Precautions]
[Wiring Precautions]
WARNING
●Shut off the external power supply (all phases) used in the system before mounting or removing the
module. Failure to do so may result in electric shock or cause the module to fail or malfunction.
CAUTION
●Use the programmable controller in an environment that meets the general specifications in the
manual "Safety Guidelines" included in the base unit. Failure to do so may result in electric shock, fire,
malfunction, or damage to or deterioration of the product.
●To mount a module, place the concave part(s) located at the bottom onto the guide(s) of the base unit,
and push in the module until the hook(s) located at the top snaps into place. Incorrect mounting may
cause malfunction, failure, or drop of the module.
●When using the programmable controller in an environment of frequent vibrations, fix the module with
a screw.
●Tighten the screws within the specified torque range. Undertightening can cause drop of the screw,
short circuit, or malfunction. Overtightening can damage the screw and/or module, resulting in drop,
short circuit, or malfunction.
●When using an extension cable, connect it to the extension cable connector of the base unit securely.
Check the connection for looseness. Poor contact may cause incorrect input or output.
●When using an SD memory card, fully insert it into the memory card slot. Check that it is inserted
completely. Poor contact may cause malfunction.
●Securely insert an extended SRAM cassette into the cassette connector of a CPU module. After
insertion, close the cassette cover and check that the cassette is inserted completely. Poor contact
may cause malfunction.
●Do not directly touch any conductive parts and electronic components of the module, SD memory
card, extended SRAM cassette, or connector. Doing so may cause malfunction or failure of the
module.
WARNING
●Shut off the external power supply (all phases) used in the system before installation and wiring.
Failure to do so may result in electric shock or damage to the product.
●After installation and wiring, attach the included terminal cover to the module before turning it on for
operation. Failure to do so may result in electric shock.

5
[Wiring Precautions]
CAUTION
●Individually ground the FG and LG terminals of the programmable controller with a ground resistance
of 100 ohm or less. Failure to do so may result in electric shock or malfunction.
●Use applicable solderless terminals and tighten them within the specified torque range. If any spade
solderless terminal is used, it may be disconnected when the terminal screw comes loose, resulting in
failure.
●Check the rated voltage and signal layout before wiring to the module, and connect the cables
correctly. Connecting a power supply with a different voltage rating or incorrect wiring may cause fire
or failure.
●Connectors for external devices or coaxial cables must be crimped or pressed with the tool specified
by the manufacturer, or must be correctly soldered. Incomplete connections may cause short circuit,
fire, or malfunction.
●Securely connect the connector to the module. Poor contact may cause malfunction.
●Do not install the control lines or communication cables together with the main circuit lines or power
cables. Keep a distance of 100 mm or more between them. Failure to do so may result in malfunction
due to noise.
●Place the cables in a duct or clamp them. If not, dangling cable may swing or inadvertently be pulled,
resulting in damage to the module or cables or malfunction due to poor contact. Do not clamp the
extension cables with the jacket stripped.
●Check the interface type and correctly connect the cable. Incorrect wiring (connecting the cable to an
incorrect interface) may cause failure of the module and external device.
●Tighten the terminal screws or connector screws within the specified torque range. Undertightening
can cause drop of the screw, short circuit, fire, or malfunction. Overtightening can damage the screw
and/or module, resulting in drop, short circuit, fire, or malfunction.
●When disconnecting the cable from the module, do not pull the cable by the cable part. For the cable
with connector, hold the connector part of the cable. For the cable connected to the terminal block,
loosen the terminal screw. Pulling the cable connected to the module may result in malfunction or
damage to the module or cable.
●Prevent foreign matter such as dust or wire chips from entering the module. Such foreign matter can
cause a fire, failure, or malfunction.
●A protective film is attached to the top of the module to prevent foreign matter, such as wire chips,
from entering the module during wiring. Do not remove the film during wiring. Remove it for heat
dissipation before system operation.
●Mitsubishi programmable controllers must be installed in control panels. Connect the main power
supply to the power supply module in the control panel through a relay terminal block. Wiring and
replacement of a power supply module must be performed by qualified maintenance personnel with
knowledge of protection against electric shock. For wiring, refer to the MELSEC iQ-R Module
Configuration Manual.
●For Ethernet cables to be used in the system, select the ones that meet the specifications in the
MELSEC iQ-R Ethernet/CC-Link IE User's Manual (Startup). If not, normal data transmission is not
guaranteed.

6
[Startup and Maintenance Precautions]
[Startup and Maintenance Precautions]
WARNING
●Do not touch any terminal while power is on. Doing so will cause electric shock or malfunction.
●Correctly connect the battery connector. Do not charge, disassemble, heat, short-circuit, solder, or
throw the battery into the fire. Also, do not expose it to liquid or strong shock. Doing so may cause the
battery to generate heat, explode, ignite, or leak, resulting in injury or fire.
●Shut off the external power supply (all phases) used in the system before cleaning the module or
retightening the terminal screws, connector screws, or module fixing screws. Failure to do so may
result in electric shock or cause the module to fail or malfunction.
CAUTION
●When connecting an external device with a CPU module or intelligent function module to modify data
of a running programmable controller, configure an interlock circuit in the program to ensure that the
entire system will always operate safely. For other forms of control (such as program modification,
parameter change, forced output, or operating status change) of a running programmable controller,
read the relevant manuals carefully and ensure that the operation is safe before proceeding. Improper
operation may damage machines or cause accidents.
●Especially, when a remote programmable controller is controlled by an external device, immediate
action cannot be taken if a problem occurs in the programmable controller due to a communication
failure. To prevent this, configure an interlock circuit in the program, and determine corrective actions
to be taken between the external device and CPU module in case of a communication failure.
●Do not disassemble or modify the modules. Doing so may cause failure, malfunction, injury, or a fire.
●Use any radio communication device such as a cellular phone or PHS (Personal Handyphone
System) more than 25 cm away in all directions from the programmable controller. Failure to do so
may cause malfunction.
●Shut off the external power supply (all phases) used in the system before mounting or removing the
module. Failure to do so may cause the module to fail or malfunction.
●Tighten the screws within the specified torque range. Undertightening can cause drop of the
component or wire, short circuit, or malfunction. Overtightening can damage the screw and/or module,
resulting in drop, short circuit, or malfunction.
●After the first use of the product, do not mount/remove the module to/from the base unit, and the
terminal block to/from the module, and do not insert/remove the extended SRAM cassette to/from the
CPU module more than 50 times (IEC 61131-2 compliant) respectively. Exceeding the limit of 50 times
may cause malfunction.
●After the first use of the product, do not insert/remove the SD memory card to/from the CPU module
more than 500 times. Exceeding the limit may cause malfunction.
●Do not touch the metal terminals on the back side of the SD memory card. Doing so may cause
malfunction or failure.
●Do not touch the integrated circuits on the circuit board of an extended SRAM cassette. Doing so may
cause malfunction or failure.
●Do not drop or apply shock to the battery to be installed in the module. Doing so may damage the
battery, causing the battery fluid to leak inside the battery. If the battery is dropped or any shock is
applied to it, dispose of it without using.

7
[Operating Precautions]
[Disposal Precautions]
●Startup and maintenance of a control panel must be performed by qualified maintenance personnel
with knowledge of protection against electric shock. Lock the control panel so that only qualified
maintenance personnel can operate it.
●Before handling the module, touch a conducting object such as a grounded metal to discharge the
static electricity from the human body. Failure to do so may cause the module to fail or malfunction.
●Before testing the operation, set a low speed value for the speed limit parameter so that the operation
can be stopped immediately upon occurrence of a hazardous condition.
●Confirm and adjust the program and each parameter before operation. Unpredictable movements
may occur depending on the machine.
●When using the absolute position system function, on starting up, and when the module or absolute
value motor has been replaced, always perform a home position return.
●Before starting the operation, confirm the brake function.
●Do not perform a megger test (insulation resistance measurement) during inspection.
●After maintenance and inspections are completed, confirm that the position detection of the absolute
position detection function is correct.
●Lock the control panel and prevent access to those who are not certified to handle or install electric
equipment.
CAUTION
●When changing data and operating status, and modifying program of the running programmable
controller from an external device such as a personal computer connected to an intelligent function
module, read relevant manuals carefully and ensure the safety before operation. Incorrect change or
modification may cause system malfunction, damage to the machines, or accidents.
●Do not power off the programmable controller or reset the CPU module while the setting values in the
buffer memory are being written to the flash ROM in the module. Doing so will make the data in the
flash ROM undefined. The values need to be set in the buffer memory and written to the flash ROM
again. Doing so also can cause malfunction or failure of the module.
●Note that when the reference axis speed is specified for interpolation operation, the speed of the
partner axis (2nd, 3rd, or 4th axis) may exceed the speed limit value.
●Do not go near the machine during test operations or during operations such as teaching. Doing so
may lead to injuries.
CAUTION
●When disposing of this product, treat it as industrial waste.
●When disposing of batteries, separate them from other wastes according to the local regulations. For
details on battery regulations in EU member states, refer to the MELSEC iQ-R Module Configuration
Manual.
CAUTION

8
[Transportation Precautions]
CAUTION
●When transporting lithium batteries, follow the transportation regulations. For details on the regulated
models, refer to the MELSEC iQ-R Module Configuration Manual.
●The halogens (such as fluorine, chlorine, bromine, and iodine), which are contained in a fumigant
used for disinfection and pest control of wood packaging materials, may cause failure of the product.
Prevent the entry of fumigant residues into the product or consider other methods (such as heat
treatment) instead of fumigation. The disinfection and pest control measures must be applied to
unprocessed raw wood.

9
CONDITIONS OF USE FOR THE PRODUCT
INTRODUCTION
Thank you for purchasing the Mitsubishi MELSEC iQ-R series programmable controllers.
This manual describes the functions and programming of the relevant products listed below. Before using this product, please
read this manual and the relevant manuals carefully and develop familiarity with the functions and performance of the
MELSEC iQ-R series programmable controller to handle the product correctly.
When applying the program examples provided in this manual to an actual system, ensure the applicability and confirm that it
will not cause system control problems.
Please make sure that the end users read this manual.
Relevant products
RD77MS2, RD77MS4, RD77MS8, RD77MS16
In this manual, buffer memories are classified using the following symbols. Each area name can represent the
buffer memories corresponding to each axis.
• [Pr.**]: Symbols indicating positioning parameter or home position return parameter items
• [Da.**]: Symbols indicating positioning data or block start data items
• [Md.**]: Symbols indicating monitor data items
• [Cd.**]: Symbols indicating control data items
(1) Mitsubishi programmable controller ("the PRODUCT") shall be used in conditions;
i) where any problem, fault or failure occurring in the PRODUCT, if any, shall not lead to any major or serious accident;
and
ii) where the backup and fail-safe function are systematically or automatically provided outside of the PRODUCT for the
case of any problem, fault or failure occurring in the PRODUCT.
(2) The PRODUCT has been designed and manufactured for the purpose of being used in general industries.
MITSUBISHI SHALL HAVE NO RESPONSIBILITY OR LIABILITY (INCLUDING, BUT NOT LIMITED TO ANY AND ALL
RESPONSIBILITY OR LIABILITY BASED ON CONTRACT, WARRANTY, TORT, PRODUCT LIABILITY) FOR ANY
INJURY OR DEATH TO PERSONS OR LOSS OR DAMAGE TO PROPERTY CAUSED BY the PRODUCT THAT ARE
OPERATED OR USED IN APPLICATION NOT INTENDED OR EXCLUDED BY INSTRUCTIONS, PRECAUTIONS, OR
WARNING CONTAINED IN MITSUBISHI'S USER, INSTRUCTION AND/OR SAFETY MANUALS, TECHNICAL
BULLETINS AND GUIDELINES FOR the PRODUCT.
("Prohibited Application")
Prohibited Applications include, but not limited to, the use of the PRODUCT in;
• Nuclear Power Plants and any other power plants operated by Power companies, and/or any other cases in which the
public could be affected if any problem or fault occurs in the PRODUCT.
• Railway companies or Public service purposes, and/or any other cases in which establishment of a special quality
assurance system is required by the Purchaser or End User.
• Aircraft or Aerospace, Medical applications, Train equipment, transport equipment such as Elevator and Escalator,
Incineration and Fuel devices, Vehicles, Manned transportation, Equipment for Recreation and Amusement, and
Safety devices, handling of Nuclear or Hazardous Materials or Chemicals, Mining and Drilling, and/or other
applications where there is a significant risk of injury to the public or property.
Notwithstanding the above, restrictions Mitsubishi may in its sole discretion, authorize use of the PRODUCT in one or
more of the Prohibited Applications, provided that the usage of the PRODUCT is limited only for the specific
applications agreed to by Mitsubishi and provided further that no special quality assurance or fail-safe, redundant or
other safety features which exceed the general specifications of the PRODUCTs are required. For details, please
contact the Mitsubishi representative in your region.

10
COMPLIANCE WITH EMC AND LOW VOLTAGE
DIRECTIVES
Method of ensuring compliance
To ensure that Mitsubishi programmable controllers maintain EMC and Low Voltage Directives when incorporated into other
machinery or equipment, certain measures may be necessary. Please refer to one of the following manuals.
MELSEC iQ-R Module Configuration Manual
Safety Guidelines (This manual is included with the base unit.)
The CE mark on the side of the programmable controller indicates compliance with EMC and Low Voltage Directives.
Additional measures
To ensure that this product maintains EMC and Low Voltage Directives, please refer to one of the following manuals.
MELSEC iQ-R Module Configuration Manual
Safety Guidelines (This manual is included with the base unit.)

11
CONTENTS
CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CONDITIONS OF USE FOR THE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
COMPLIANCE WITH EMC AND LOW VOLTAGE DIRECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
RELEVANT MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CHAPTER 1 OUTLINE OF SYNCHRONOUS CONTROL 15
1.1 Outline of Synchronous Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Operation Method of Synchronous Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Synchronous control execution procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starting/ending for synchronous control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stop operation of output axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CHAPTER 2 INPUT AXIS MODULE 24
2.1 Servo Input Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overview of servo input axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Servo input axis parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Servo input axis monitor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Synchronous Encoder Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Overview of synchronous encoder axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Setting method for synchronous encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Synchronous encoder axis parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Synchronous encoder axis control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Synchronous encoder axis monitor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHAPTER 3 CAM FUNCTION 48
3.1 Control Details for Cam Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Create Cam Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Memory configuration of cam data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cam data operation function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cam auto-generation function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CHAPTER 4 SYNCHRONOUS CONTROL 61
4.1 Main Shaft Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Overview of main shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Main shaft parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Main shaft clutch parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Main shaft clutch control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2 Auxiliary Shaft Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Overview of auxiliary shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary shaft parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary shaft clutch parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Auxiliary shaft clutch control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Overview of clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control method for clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

12
Smoothing method for clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Use example of clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Speed Change Gear Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Overview of speed change gear module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Speed change gear parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.5 Output Axis Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Overview of output axis module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Output axis parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.6 Synchronous Control Change Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Overview of synchronous control change function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Synchronous control change control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.7 Synchronous Control Monitor Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.8 Phase Compensation Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.9 Output Axis Sub Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
CHAPTER 5 SYNCHRONOUS CONTROL INITIAL POSITION 106
5.1 Synchronous Control Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.2 Synchronous Control Initial Position Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.3 Cam Axis Position Restoration Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Cam axis current value per cycle restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Cam reference position restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cam axis feed current value restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4 Synchronous Control Analysis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.5 Cam Position Calculation Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Cam position calculation control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Cam position calculation monitor data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.6 Method to Restart Synchronous Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
APPENDICES 128
Appendix 1 List of Buffer Memory Addresses (for Synchronous Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Appendix 2 Sample Program of Synchronous Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INDEX 138
REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
TRADEMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

13
RELEVANT MANUALS
This manual does not include information on the module function blocks.
For details, refer to the Function Block Reference for the module used.
e-Manual refers to the Mitsubishi FA electronic book manuals that can be browsed using a dedicated tool.
e-Manual has the following features:
• Required information can be cross-searched in multiple manuals.
• Other manuals can be accessed from the links in the manual.
• The hardware specifications of each part can be found from the product figures.
• Pages that users often browse can be bookmarked.
Manual name [manual number] Description Available form
MELSEC iQ-R Simple Motion Module User's Manual
(Advanced Synchronous Control)
[IB-0300249] (This manual)
Functions and programming for the synchronous control of the
Simple Motion module
Print book
e-Manual
EPUB
PDF
MELSEC iQ-R Simple Motion Module User's Manual
(Application)
[IB-0300247]
Functions, input/output signals, buffer memories, parameter
settings, programming, and troubleshooting of the Simple Motion
module
Print book
e-Manual
EPUB
PDF
MELSEC iQ-R Simple Motion Module User's Manual
(Startup)
[IB-0300245]
Specifications, procedures before operation, system configuration,
wiring, and operation examples of the Simple Motion module
Print book
e-Manual
EPUB
PDF

14
TERMS
Unless otherwise specified, this manual uses the following terms.
*1 SSCNET: Servo System Controller NETwork
Term Description
CPU module Abbreviation for the MELSEC iQ-R series CPU module.
Simple Motion module Abbreviation for the MELSEC iQ-R series Simple Motion module.
RD77MS Another term for the MELSEC iQ-R series Simple Motion module.
Servo amplifier Abbreviation for SSCNET/H and SSCNETcompatible servo amplifier.
MR-J4(W)-B MR-J4-_B/MR-J4W_-_B Servo amplifier series
MR-J3(W)-B MR-J3-_B/MR-J3W-_B Servo amplifier series
MR-JE-B MR-JE-_B Servo amplifier series
Engineering tool Generic term for GX Works3 and MR Configurator2.
GX Works3 Product name of the software package for the MELSEC programmable controllers.
MR Configurator2 Product name of the setup software for the servo amplifier (Version 1.27D or later).
Intelligent function module A MELSEC iQ-R series module that has functions other than input or output, such as A/D converter module and D/A
converter module
Manual pulse generator Abbreviation for manual pulse generator (prepared by user).
SSCNET/H*1 High speed synchronous communication network between RD77MS and servo amplifier.
SSCNET*1
SSCNET(/H) Generic term for SSCNET/H, SSCNET.
Servo network
2-axis module Generic term for RD77MS2.
4-axis module Generic term for RD77MS4.
8-axis module Generic term for RD77MS8.
16-axis module Generic term for RD77MS16.

1 OUTLINE OF SYNCHRONOUS CONTROL
1.1 Outline of Synchronous Control 15
1
1OUTLINE OF SYNCHRONOUS CONTROL
The outline, specifications and the operation method of synchronous control using the Simple Motion module are explained in
this chapter.
This chapter helps to understand what can be done using the positioning system and which procedure to use for a specific
purpose.
1.1 Outline of Synchronous Control
"Synchronous control" can be achieved using software instead of controlling mechanically with gear, shaft, speed change
gear or cam, etc.
"Synchronous control" synchronizes movement with the input axis (servo input axis or synchronous encoder axis), by setting
"the parameters for synchronous control" and starting synchronous control on each output axis.
*1 It is possible to drive the servo input axis except for the positioning control (home position return, manual control, speed-torque control,
synchronous control).
For details on the positioning control, the home position return, the manual control and the speed-torque control, refer to the following
manual of the Simple Motion module that is used.
User's Manual (Application)
*2 Speed change gear can be arranged on one of "Main shaft side", "Auxiliary shaft side" or "After composite auxiliary shaft gear".
Positioning data
Positioning control
Positioning start Synchronous control start Synchronous control start
Synchronous encoder axis
Servo input axis
*1
Synchronous parameter
Synchronous control start
It is possible to control without amplifier
by setting the virtual servo amplifier.
Cam data
Output axis
Speed
change
gear *2
Speed
change
gear *2
Speed
change
gear
Auxiliary
shaft axis Cam
Synchronous
encoder
Manual pulse generator/
Synchronous encoder input Simple Motion module
Synchronous
encoder axis
parameter
Servo input axis
parameter
Auxiliary
shaft
clutch
Servo
amplifier
Servo
motor
Servo
amplifier
Servo
motor
Servo
motor
Servo
motor
Servo
amplifier
Servo
amplifier
Auxiliary
shaft
gear
Main shaft
(sub input axis)
Main shaft
(main input axis)
Composite
main shaft gear
Main shaft gear
Main shaft
clutch
Composite
auxiliary shaft
gear
*2

16 1 OUTLINE OF SYNCHRONOUS CONTROL
1.1 Outline of Synchronous Control
List of synchronous control module
The module is used in synchronous control as follows.
• Input axis module can be set to one of servo input axis or synchronous encoder axis.
• Speed change gear can be arranged on one of main shaft side, auxiliary shaft side or after composite
auxiliary shaft gear.
• Set the movement amount of input axis module as large as possible to prevent the speed fluctuation of
output axis module in the synchronous control. If the movement amount of input axis module is small, the
speed fluctuation of output axis module may occur depending on the setting for synchronous parameter.
• The following items can be monitored using the Simple Motion Module Setting Function; each synchronous
control monitor data and rotation direction of main shaft main input axis, main shaft sub input axis, auxiliary
shaft axis, and output axis (cam axis feed current value)
■Input axis
Classification Name Parts Function description Maximum number of usable Reference
Number per module Number
per axis
2-axis
module
4-axis
module
8-axis
module
16-axis
module
Input axis
module
Servo input
axis
• Used to drive the input axis with
the position of the servomotor
controlled by the Simple Motion
module.
24816Page 24
Servo Input
Axis
Synchronous
encoder axis
• Used to drive the input axis with
input pulse from the
synchronous encoder.
4Page 31
Synchronous
Encoder Axis
Synchronous parameter
Synchronous encoder
axis parameter
Synchronous encoder axis
Servo input axis
parameter
Servo input axis
Input axis module
Main shaft module
Output axis
module
Cam data
Speed change
gear module
Auxiliary shaft module
Main shaft
(main input axis)
Auxiliary
shaft
clutch
Auxiliary
shaft
gear
Main shaft
(sub input axis)
Main shaft
gear
Main shaft
clutch
Composite
auxiliary
shaft gear
Composite main
shaft gear
Output axis
Speed
change
gear
Auxiliary shaft axis
Cam

1 OUTLINE OF SYNCHRONOUS CONTROL
1.1 Outline of Synchronous Control 17
1
■Output axis
■Cam data
Classification Name Parts Function description Maximum number of usable Reference
Number per module Numbe
r per
axis
2-axis
module
4-axis
module
8-axis
module
16-axis
module
Main shaft
module
Main shaft
main input
axis
• The input axis on the main
side of the main shaft module.
• The reference position on the
main shaft.
248161Page 61
Main Shaft
Module
Main shaft
sub input
axis
• The input axis on the sub side
of the main shaft module.
• It is used to input the
compensation amount for the
position of the main shaft main
input axis.
248161Page 61
Main Shaft
Module
Composite
main shaft
gear
• The composite movement
amount of the main shaft main
input axis and the main shaft
sub input axis are transmitted
to the main shaft gear.
248161Page 61
Main Shaft
Module
Main shaft
gear
• The converting movement
amount after composite main
shaft gear is transmitted by
the setting gear ratio.
248161Page 61
Main Shaft
Module
Main shaft
clutch
• The movement amount of the
main shaft is transmitted by
the clutch ON/OFF.
248161Page 61
Main Shaft
Module
Page 77
Clutch
Auxiliary shaft
module
Auxiliary
shaft axis
• The input axis of the auxiliary
shaft module.
248161Page 69
Auxiliary Shaft
Module
Auxiliary
shaft gear
• The converting movement
amount of the auxiliary shaft is
transmitted by the setting gear
ratio.
248161Page 69
Auxiliary Shaft
Module
Auxiliary
shaft clutch
• The movement amount of the
auxiliary shaft is transmitted
by the clutch ON/OFF.
248161Page 69
Auxiliary Shaft
Module
Page 77
Clutch
Composite
auxiliary
shaft gear
• The composite movement
amount of the main shaft and
the auxiliary shaft are
transmitted.
248161Page 69
Auxiliary Shaft
Module
Speed change
gear module
Speed
change
gear
• It is used to change the speed
by setting speed change ratio
during the operation.
248161Page 88
Speed
Change Gear
Module
Output axis
module
Output axis • The cam conversion is
processed based on the input
movement amount and the
setting cam data.
• The feed current value is
output as the command to the
servo amplifier.
248161Page 90
Output Axis
Module
Classification Name Function description Maximum number of usable Reference
Number per module
Cam data Cam data • It controls the operation pattern of the output axis (two-way
operation and feed operation), which is corresponding to the
input movement amount of the output axis module.
Up to 256 Page 48
CAM
FUNCTION

18 1 OUTLINE OF SYNCHRONOUS CONTROL
1.2 Performance Specifications
1.2 Performance Specifications
Performance specifications
Cam specifications
*1 The maximum number of cam registration by the cam resolution is shown below. (In case it created by the same cam resolution.)
Item Number of settable axes
2-axis module 4-axis module 8-axis module 16-axis module
Input axis Servo input axis 2 axes/module 4 axes/module 8 axes/module 16 axes/module
Synchronous encoder
axis
4 axes/module
Composite main shaft gear 1/output axis
Main shaft main input axis 1 axis/output axis
Main shaft sub input axis 1 axis/output axis
Main shaft gear 1/output axis
Main shaft clutch 1/output axis
Auxiliary shaft 1 axis/output axis
Auxiliary shaft gear 1/output axis
Auxiliary shaft clutch 1/output axis
Composite auxiliary shaft gear 1/output axis
Speed change gear 1/output axis
Output axis (Cam axis) 2 axes/module 4 axes/module 8 axes/module 16 axes/module
Item Specification
Memory capacity Cam storage area 256k bytes
Cam open area 1024k bytes
Number of cam registration*1 Up to 256
(Dependent on memory capacity, cam resolution and coordinate number)
Comment Up to 32 characters per cam data
Cam data Stroke ratio data format Cam resolution 256/512/1024/2048/4096/8192/16384/32768
Stroke ratio -214.7483648 to 214.7483647 [%]
Coordinate data format Coordinate number 2 to 16384
Coordinate data Input value: 0 to 2147483647
Output value: -2147483648 to 2147483647