NPM PCL-240 Series User manual

Pulse Control LSIs
Basic Description for PCL Series
Nippon Pulse Motor Co., Ltd.
I
In ns st tr ru uc ct ti io on n d do oc cu um me en nt ts s

Table of contents
I. Outline ････････････････････････････････････････････････････････････････1
1. PCL-240 family ･･････････････････････････････････････････････････････････････ 1
2. PCL50oo series ･････････････････････････････････････････････････････････････ 1
3. PCL61oo series / 60oo series ･････････････････････････････････････････････････ 1
II. Differences between the PCL series and PCD series
･･････････････････････
2
1. Which should be selected? ･･･････････････････････････････････････････････････ 2
Comparison of the basic functions
in the PCD45oo, PCL61oo, and PCL60oo series
･･････････････････････････････
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2. PCL series features in Table 1 above. ･･････････････････････････････････････････ 2
III. Major additional facilities and functions of the PCL series
････････････････
3
1. Encoder input
(A/B phase signal (90˚phase difference signal) or bi-directional pulse signals)･･･ 3
2. Up/down counter ････････････････････････････････････････････････････････････ 3
3. Servomotor interface ････････････････････････････････････････････････････････ 3
4. Pre-register (preliminary buffer for the next operation) ･･････････････････････････ 4
5. Rampdown point auto setting function ････････････････････････････････････････ 5
6. S-curve range setting ････････････････････････････････････････････････････････ 7
7. Operating speed correction function (FH correction function)････････････････････ 8
8. Various zero return methods･･････････････････････････････････････････････････ 8
9. Comparator ･････････････････････････････････････････････････････････････････10
10. Pulsar input･････････････････････････････････････････････････････････････････13
11. Stepper motor out-of-step detection function･･･････････････････････････････････14
Instructions for the PCL60oo series
Outline
･･･････････････････････････････････････････････････････････････
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Features
･････････････････････････････････････････････････････････････
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POINT 1. Interpolation operation
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What is linear interpolation?
････････････････････････････････････････････････････
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What is arc interpolation?
･･････････････････････････････････････････････････････
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What is synthesized constant speed control?
････････････････････････････････････
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POINT 2. Continuous operation using the pre-registers
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What is a pre-register?
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POINT 3. Various acceleration/deceleration patterns
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POINT 4. Target position and speed override during operation
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[Target position override] ･･･････････････････････････････････････････････････18
[Operation speed override]･･････････････････････････････････････････････････19
POINT 5. Smooth the speed curve by using the FH correction function
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What is the FH correction function?
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POINT 6. A variety of counters and comparators are built in
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POINT 7. Other useful functions
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■Manual operation input･･･････････････････････････････････････････････････････21
■Synchronous start control････････････････････････････････････････････････････21
■CPU-I/F ･････････････････････････････････････････････････････････････････････21
■Idling pulse outputs･･････････････････････････････････････････････････････････21
■Backlash correction / slip correction ･･････････････････････････････････････････21
■Vibration restriction function ･････････････････････････････････････････････････21
■Simultaneous start / simultaneous stop････････････････････････････････････････21
■Mechanical input signals ･････････････････････････････････････････････････････22
■Servomotor I/F ･･････････････････････････････････････････････････････････････22
■Output pulse specification････････････････････････････････････････････････････22
■Emergency stop signal input ･････････････････････････････････････････････････22
■Interrupt signal output ･･･････････････････････････････････････････････････････22
POINT 8. A variety of operation modes
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Basic description of PCL series
-1-
Basic Description for PCL Series
This document outlines the major functions of the PCL series pulse control LSIs, which are not part of the PCD
series
I. Outline
The PCD/PCL series pulse control LSIs manufactured by NPM now have a varied lineup. These products (17
models) can be divided into the following three groups, according to their command functions and registers.
･PCL-240 family
PCD4500/4511/4521/4541
PCL-240AK/240MK/240AS/240MS
･PCL50oo family (PCL50oo series)
PCL3013/5014
PCL5022/5023
･PCL60oo family (PCL61oo series/60oo series)
PCL6113/6123/6143
PCL6025/6045B
1. PCL-240 family
In this family, each command is allocated a specific bit.
Basically, this is a simple family that has only four modes: start mode, control mode, register select mode, and
an output mode (8 bits are used for each mode). Since the PCL-240 series has a larger number of functions
than the PCD series, some commands for additional functions are accessed through registers.
2. PCL50oo series
The PCL55oo series has many more functions than the PCL-240 family, with lots of commands and registers.
The method for writing and reading this series is different from the PCL-240 family.
The PCL5022/5023 are LSIs for controlling two axes. The specifications for these LSIs when working on one
axis are not as broad as the PCL5014, which can be used for linear interpolation. (For details about linear
interpolation, see the user's manual for each model, or see page 17 in this document.)
3. PCL61oo series / 60oo series
The PCL60oo series has still more functions than the PCL50oo series, such as lots of counters, comparators,
and an arc interpolation function (see page 16). The bits for commands, registers, and status conditions have
been named for easy reference. This series contains the best models we offer.
PCL61oo series has fewer functions than the PCL60oo series, and they cost much less as well. Even though
the functions are limited, the basic high level functions are still present, such as servomotor control and linear
interpolation. The power supply requirement is just 3.3 V. They offer the highest output frequency offered by
the NPM pulse control LSIs, and they can control high-resolution linear motors.
• When our models are classified by compatibility with software programs, there are 6 types, as shown
below:
(1) PCD4500/4511/4521/4541
(2) PCL-240AK/240MK/240AS/240MS
(3) PCL3013/5014
(4) PCL5022/5023
(5) PCL6113/6123/6143
(6) PCL6025/6045B

Basic description of PCL series
-2-
II. Differences between the PCL series and PCD series
1. Which should be selected?
Except for the excitation sequence output for a 4-pole (2-pole) stepper motor, there are no functions found in
the PCD series which are not found in the PCL series,
The PCD series have the minimum required functions for controlling stepper motors. In addition to these
functions, the PCL series can handle servomotors and are equipped with the various interfaces, encoder
inputs, and up/down counters that are needed to control servomotors. The registers related to speed patterns
have more bits to handle the high speeds of servomotors.
Each model also has other functions. However, to make the selection simple, if you want to control a closed
loop system using position detection equipment such as encoders, you should first consider using the PCL
series. If you want to control an open loop system using stepper motors, you should first consider using the
PCD series.
Table 1 sums up the basic performance offerings of the PCD series, PCL61oo series, and PCL60oo series.
Comparison of the basic functions in the PCD45oo, PCL61oo, and PCL60oo series
Model
Function PCD4511/4521/4541 PCL6113/6123/6143 PCL6025/6045B
Number of axes controlled 1/2/4 1/2/4 2/4
Standard reference clock
frequency 4.9152 MHz 19.6608 MHz (Max. 30 MHz) 19.6608 MHz (Max. 20 MHz)
Maximum pulse output
frequency 2.4 Mpps 9.8 Mpps (Max. 15 MHz) 6.5 Mpps
Number of registers for
specifying speed 2 (FL, FH) 2 (FL, FH) 3 (FL､FH､FA (for correction))
Number of speed step settings 8,191 (13 bits) 16,383 (14 bits) 65,535 (16 bits)
Speed multiplication range 1x to 300x 0.3x to 600x 0.1x to 100x
Acceleration rate range 1 to 16,383 (14 bits) 1 to 65,535 (16 bits)
Deceleration rate range
2 to 1,023 (10 bits)
(Used for both
acceleration/deceleration) 1 to 16,383 (14 bits) 1 to 65,535 (16 bits)
Positioning pulse range
(countdown counter) 0 to 16,777,215 (24 bits) -134,217,728 to +134,217,727 (28 bits)
-134,217,728 to +134,217,727
(28 bits)
CPU interface 8-bit bus 16-bit bus 16-bit bus
Rampdown point range 1 to 65,535 (16 bits) 1 to 16,777,215 (24 bits) 1 to 16,777,215 (24 bits)
<Table 1>
2. PCL series features in Table 1 above.
(1) The is a large number of speed steps.
=> Can output high frequency pulses with low speed multiplication.
=> Finer tuning of the speed setting is possible.
=> When the speed setting registers (FH or FL speeds) are set to the same values as in the PCD, the speed
multiplication rate can be set between 1/2 to 1/8.
(2) The acceleration and deceleration rates can be set independently.
=> For example, a short acceleration with a long deceleration is easily set. (Except for the PCL3013.)
(3) The setting range of the acceleration, deceleration rates, and the rampdown point is larger.
=> In the PCD series, these setting ranges are rather small, which places some restrictions on the
acceleration speed and the speed setting. In the PCL series, there is almost no restriction when setting
the maximum speed.
As shown above, the PCL series has almost no restriction on its operation, compared with
the PCD series.

Basic description of PCL series
-3-
III. Major additional facilities and functions of the PCL series
Though we cannot describe everything in detail here, this section will introduce the remarkable functions of the
PCL that are not found on the PCD series. (For an outline of all the functions, see the function description list.)
The symbols next to the additional functions or capabilities have the following meaning:
240 -> PCL-240 series function (except for the PCD series)
50oo -> PCL50oo series function
61oo -> PCL6100 series function
60oo -> PCL60oo series function
1. Encoder input (A/B phase signal (90˚phase difference signal) or bi-directional pulse signals)
240 50oo 61oo 60oo
Mainly used to input signals from an encoder mounted on a servomotor. In some applications, an encoder is
mounted on a stepper motor to control the current position.
Encoder signals are input on the EA/EB terminals on the PCL50oo/61oo/60oo series.
The input signal type can be either an A/B phase signal (90˚phase difference signals) or a bi-directional pulse
(positive and negative direction pulses). If A/B phase signals are selected, they can be multiplied by 2x or 4x.
Normally rotation type encoders are mounted at the back of the servomotor. Recently, however, linear type
encoders are being installed on linear motion stages that use linear motors.
An EZ encoder input terminal is available (except on the PCL-240AK) for inputting the Z-phase signal, that is
output once per rotation of the encoder. This is usually used, together with the ORG signal, to perform a
precision zero return positioning operation.
2. Up/down counter 240 50oo 61oo 60oo
The PCD series only have a down counter. However, the PCL series have an up/down counter as well as a
down counter. The up/down counter counts up while the motor is rotating in a positive direction and it counts
down while the motor is rotating in a negative direction.
This counter is mainly used to count A/B phase signals from the encoder.
Since the counter is counting signals from the encoder, you can know the exact current position at the moment
you read this counter.
This counter also can be used in the following way:
- Set it to not count when pulse signals are input, such as A/B phase signals.
- In addition to A/B phase signals, bi-directional pulse signals, which use so called positive and negative
direction pulses, can also be counted.
- In addition to external signals, such as A/B phase signals and bi-directional pulses, the counter can also
count pulses output by the PCL itself.
3. Servomotor interface 240 50oo 61oo 60oo
These LSIs have INP, ERC, and ALM terminals for making connections to a servo driver. For details about the
roles and functions of each signal, see the "Basics of servo motor control" and the " Function description list"
pamphlets.

Basic description of PCL series
-4-
4. Pre-register (preliminary buffer for the next operation) 50oo (Except PCL5022/5023) 61oo 60oo
The term pre-register refers to a register used to prepare for operation.
Simply put, this is just like a waiting room where the data for the next speed pattern is stored.
As you can see in <Table 2> below, the pre-registers are provided primarily for registers that determine speed
patterns.
Registers that have pre-registers
Register name
Register details PCL3013/5014 PCL6113/6123/6143 PCL6025/6045B
Feed amount (preset amount or target
position) R0 RMV RMV
FL speed R1 RFL RFL
FH speed R2 RFH RFH
Acceleration rate R3 RUR RUR
Deceleration rate R15 RDR RDR
Speed multiplication rate R4 RMG RMG
Rampdown point R5 RDP RDP
Operation mode Operation mode buffer RMD RMD
Center position during arc interpolation, or
main axis feed amount during linear
interpolation
- RIP RIP
S-curve range during S-curve acceleration RUS RUS
S-curve range during S-curve deceleration
R16
(shared for both
acceleration /
deceleration) RDS RDS
Start command With preliminary buffer
<Table 2>
On the models that do not have pre-registers (PCD series, PCL-240 series, and PCL5022/5023), if you want to
use next different operating pattern after completing one operation, first the LSI confirms the end of the
previous operation using the INT signal or a status register. After confirming this, you have to write the data for
the next operation (preset amount, FL/FH speed, acceleration/deceleration rate, multiplication etc.) from a
CPU. If the register value is the same as in the previous operation, you only write the preset amount and any
other values you want to change. The time required to confirm the end of previous operation and write the data
for the next operation is only a few µs. However, this interval is simply waiting time before the ultimate
operation begins.
With pre-registers, you can write the data for the next operation during the current operation, so that the next
data are available as soon as they can be used. Then, the LSI can start the next operation immediately,
without the waiting time described above.
The operating pattern is a chain of multiple patterns, as shown in Figure 2.
During this interval, the LSI confirms that operation (1) has stopped and writes the register
values and commands for operation (2). Therefore, there is a period when everything stops,
even though it is very short. (The same is true for the time between operations (2) and (3), etc.)
- Without pre-registers
ｔ
ｆ
(1) (2)
(3)
<Figure 1>

Basic description of PCL series
-5-
In another application, drawing a freestyle curve
(a sequence of short line segments) changes in
the speed are possible, as shown in Figure 3.
In order to start the next operation by eliminating the waiting time, you have to write the data to each of
pre-registers for the speed pattern settings, as well as the next operation’s start command.
The actual procedure is as follows. To operate a motor with the pattern shown in Figure 2, do the following:
a) First, write the values for operation (1) in each pre-register.
b) Write a start command. The moment the start command is written, all of the values are copied into the
appropriate operation registers and the LSI starts operation.
c) After starting operation, the values for operation (2) must be written to the LSI. However, the pre-registers
still contain the values that were written in step a) above, so you only need to overwrite those values that
are different from operation (1). (However, the feed amount [preset amount or target position] still needs to
be written again, even if the value is the same as in the previous operation, because the counter is reset to
zero when the current operation is complete.)
d) During the execution of operation (1), write the next operation start command.
e) After operation (2) has started, repeats step c) and d) for subsequent operations.
5. Rampdown point auto setting function 240 50oo 61oo 60oo
For positioning operations (preset operations) with the PCD series, we have to set a rampdown point
(deceleration start point) for acceleration/deceleration operations, in order to tell the LSI the number of residual
pulses at which to start deceleration.
All models in the PCL series have a rampdown point auto setting function. Using this function, you don’t need
to write the rampdown point setting register for each operation.
There are two ways to think about using the PCL series rampdown point auto setting function.
Using pre-registers, the LSI can prepare the data for the next operation during the current
operation, so that no time is lost between operations.
- With pre-registers
ｔ
ｆ
(2)(1)
(3)
<Figure 2>
<Figure 3>
ｆ
ｆＬ
ｆ３
ｆ４
ｆ２
ｆ１
Ｐ５ Ｐ１ Ｐ４ Ｐ３ Ｐ２
ｔ

Basic description of PCL series
-6-
(1) Count Method (PCL-240AK/240MK,3013,5022,6113/6123/6143)
This system counts the number of pulses used for acceleration (the number of pulses between FL and FH
speed). When the number of residual pulses is equal to this amount, the LSI starts the deceleration.
This method requires the (acceleration time) = (deceleration time). If you want to change the deceleration time
(if you want to have an asymmetrical pattern, you have to disable the auto setting of the rampdown start point.
In this case you will have to write a value into the rampdown point setting register, just like with the PCD series.
(This is generally referred to manual rampdown point setting.)
(2) Calculation Method (PCL-240AS/240MS,5014,5023,6025/6045B)
In contrast with the Count Method (1), this method always calculates the number of pulses required to
deceleration rate and stop. The calculated result is used as the rampdown point.
The advantage of this method is that the deceleration time can be different from the acceleration time.
(Asymmetrical speed patterns are possible) => This was designed for users who want the deceleration time
to be shorter than the acceleration time that would be set using the rampdown point auto setting function.
Count method
<Figure 4>
Counts the number of pulses
needed for acceleration,
Then, sets the same number of
pulses as the rampdown point.
When the number of pulses used for the
acceleration is equal to the number of
residual pulses, the LSI starts the
deceleration.
ｆ
ｔ
FH
FL
Calculation
method
<Figure 5>
Start decelerating using the deceleration rate that is set.
Calculates the number of pulses needed to reach FL speed from the current FH
speed, using the current deceleration rate and use this value as the rampdown point.
ｆ
ｔ
FL
FH

Basic description of PCL series
-7-
6. S-curve range setting 240 (except for the PCL-240AK/240MK), 50oo (except for the PCL3013/5022), 61oo 60oo
With a normal S-curve, the center point of the
S-curve (point A in Figure 6) has the largest
acceleration rate (a steep slope).
This means that the motor must accelerate
rapidly at this point. So, the stepper motor may
get out-of-step.
PCL series models that have S-curve
acceleration / deceleration can make this
intermediate part a straight line (except for PCD
series and the PCL3013). By providing a straight
line here, the acceleration rate will be smaller
(the slope will be less steep) and an out-of-step
condition can be prevented.
By setting the S-curve range, the length of the
straight line can be set freely.
<Figure 6>
Point A (A large rate of
acceleration. By drawing the
tangent, you can see how
steep the slope is.)
ＦＬ
ＦＨ
ｔ
ｆ
ｆ
<Figure 7>
By insetting a straight line,
the acceleration rate will
be smaller (the slope will
be less steep).
ＦＬ
ＦＨ
ｔ
S-curve range