Omron C200H-MC221 - User manual

Cat. No.W314-E1-1
Motion ControlUnit
C200H-MC221
OPERATIONMANUAL:
INTRODUCTION

C200H-MC221
Motion ControlUnit
Operation Manual:
Introduction
Produced June 1996

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Notice:
OMRONproductsaremanufactured foruse according to properproceduresbya qualified operator
and onlyforthe purposesdescribed inthismanual.
The following conventionsare used toindicate and classifyprecautionsinthismanual.Always heed
the information provided withthem.Failureto heed precautions can resultininjuryto people ordam-
age tothe product.
DANGER!Indicatesinformation that, ifnotheeded,islikelytoresultinloss oflife orseriousinjury.
WARNINGIndicatesinformation that, ifnotheeded,could possiblyresultinloss oflife orseriousinjury.
Caution Indicatesinformationthat, ifnotheeded,couldresultinrelativelyseriousorminorinjury,dam-
age tothe product, orfaultyoperation.
OMRONProductReferences
All OMRONproductsarecapitalized inthismanual.The word“Unit”isalsocapitalized when itrefers
to an OMRONproduct, regardless ofwhetherornotitappearsinthe propername of the product.
The abbreviation “Ch,”which appearsinsome displays and on someOMRONproducts,often means
“word”and isabbreviated “Wd”in documentation inthis sense.
The abbreviation “PC”meansProgrammableControllerand isnotused asan abbreviation forany-
thing else.
VisualAids
The following headingsappearinthe left column of the manualto helpyou locate different typesof
information.
NoteIndicatesinformation ofparticularinterest forefficientand convenientoperation
of the product.
1,2,3... 1. Indicateslistsofone sortoranother,such asprocedures,checklists,etc.
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All rightsreserved.No partofthispublication may bereproduced,storedinaretrievalsystem,ortransmitted,inany
form,orby any means,mechanical,electronic,photocopying,recording,orotherwise,without thepriorwritten permis-
sion ofOMRON.
No patent liabilityisassumedwithrespect totheuseoftheinformation contained herein.Moreover,becauseOMRON is
constantlystriving toimproveitshigh-quality products,theinformation containedinthismanual is subject tochange
withoutnotice.Every precaution hasbeentakeninthepreparation ofthismanual.Nevertheless,OMRON assumesno
responsibilityforerrorsoromissions.Neitherisany liabilityassumedfordamagesresulting fromtheuseoftheinforma-
tion containedinthispublication.

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TABLE OFCONTENTS
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PRECAUTIONSxi.................................
1IntendedAudience xii...........................................................
2GeneralPrecautionsxii..........................................................
3SafetyPrecautionsxii...........................................................
4Operating EnvironmentPrecautionsxii.............................................
5Application Precautionsxiii......................................................
SECTION1
Introduction1....................................
1-1CWand CCW2...........................................................
1-2FeedbackPulse2..........................................................
1-3CoordinateSystems3......................................................
1-4ApplicableMachines3.....................................................
1-5Wiring Precautions4.......................................................
1-6SystemConfiguration 6.....................................................
1-7OutlineoftheInterface Area 7...............................................
1-8DataConfiguration 7.......................................................
1-9Programsand Tasks8......................................................
1-10 Manualand AutomaticOperation 9...........................................
SECTION2
Features11.......................................
2-1Features12...............................................................
2-2Specifications14...........................................................
2-3OutsideDimensions15......................................................
2-4Functions16..............................................................
SECTION3
Servo SystemPrinciplesand Precautions19............
3-1Servo System20...........................................................
3-2MotorRunaway 23.........................................................
3-3Wiring CheckFunction 25...................................................
3-4FailsafeCircuits26.........................................................
SECTION4
SystemConfiguration29............................
4-1BasicSystemConfiguration 30................................................
4-2ItemsSupplied by theUser31................................................
4-3PeripheralDevices32.......................................................
SECTION5
Positioning 35.....................................
5-1Positioning Controls36......................................................
5-2PTPControl37............................................................
5-3Linear Interpolation 38......................................................
5-4Circular Interpolation 40.....................................................
5-5InterruptInching 41.........................................................
5-6Acceleration and Deceleration Curves41.......................................
5-7Operation Modes42........................................................
5-8OverrideFunction 44.......................................................
5-9BacklashCompensation 45...................................................
SECTION6
GLanguage47....................................
6-1Introduction 48............................................................
6-2G-languageSymbols51.....................................................

TABLE OFCONTENTS
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SECTION7
PreparationsforOperation53........................
7-1SystemStartup Procedures54.................................................
7-2Testing EquipmentConfiguration 55...........................................
7-3ItemstoBePrepared 55.....................................................
7-4Positioning Operations56....................................................
7-5Interface Area 58...........................................................
SECTION8
TestOperation63..................................
8-1Mounting theUnits64.......................................................
8-2Connecting theComputer65.................................................
8-3Connecting theTeaching Box 68..............................................
8-4Wiring I/OConnectors70....................................................
8-5Connecting Servodrivers72..................................................
8-6Wiring InputUnits73.......................................................
8-7Starting UpthePC74.......................................................
8-8Setting Parameters74.......................................................
8-9Saving Parameters81.......................................................
8-10 Transferring Parameters82...................................................
8-11 FlashMemoryBackup ofParameter84.........................................
8-12 Creating MCPrograms85....................................................
8-13 Saving MCPrograms87.....................................................
8-14 Transferring MCPrograms89................................................
8-15 FlashMemoryBackup ofMCProgram91.......................................
8-16 Creating Ladder-diagramPrograms92..........................................
8-17 Checking Operation fromtheMCSS 94.........................................
8-18 Checking Operation fromtheTeaching Box 98...................................
Glossary 103.......................................
Index 109..........................................
RevisionHistory 113.................................

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About thisManual:
Thismanualprovidesan introduction tothe featuresand basicoperation of the C200H-MC221 Motion
ControlUnitand includesthe sectionsdescribed below.
Pleaseread thismanualand the othermanualsrelated tothe C200H-MC221 Motion ControlUnitcareful-
lyand be sureyou understand the information provided before attempting toinstall and operatethe Mo-
tion ControlUnit.
There arefourmanualsused withthe C200H-MC221 Motion ControlUnit(MC Unit).Thesemanualsare
listed inthe following table.The suffixeshave been left off of the catalog numbers.Besureyou are using
the mostrecentversion foryourarea.Be suretoreadtheprecautionsinthefollowing section.
NameContentCat.No.
C200H-MC221 Motion ControlUnit
Operation Manual: Introduction Describesthe features,applications,and basicoperation of the Motion ControlUnits.Read thismanualfirstbefore us-
ing a Motion ControlUnit.
W314
C200H-MC221 Motion ControlUnit
Operation Manual:DetailsDescribesoperation of the Motion ControlUnitsin detail. Read the Operation Manual: Introduction,above,before
attempting toread thismanual.
W315
CVM1-PRS71 Teaching Box
Operation ManualDescribesthe operation of the Teaching Box connected to a Motion ControlUnit. W257
CV500-ZN3AT1-EMCSupport
SoftwareOperation ManualDescribes creating controlprogramsand setting operating parametersforMC Unitsusing the MCSupportSoftware.W256
Section 1describesfundamentalsnecessaryforunderstanding thismanualand forthe successfulop-
eration ofan MC Unit.
Section 2describesthe featuresand functionsof the MC Unit.
Section 3providesinformation on the servosystem,basicmechanismsforpositioning,and precautions
to be heeded in using the system.
Section 4providesinformation on the systemconfiguration necessaryforoperating the MC Unit.
Section 5providesinformation on position controlasperformed bythe MC Unit.
Section 6introducesthe “G”language used forposition controlwiththe MC Unit.
Section 7providesinformation on startup procedures,systemconfiguration,and positioning operations
using testing equipment, aswell asexplanationson the interface area necessaryforcreating ladderpro-
grams.
Section 8describesthe proceduresinvolved inconducting testsusing testequipment.
WARNINGFailuretoread and understand the information provided inthismanualmayresultin
personal injuryordeath,damage tothe product, orproduct failure.Pleaseread each
section initsentiretyand be sureyou understand the information provided inthe section
and related sectionsbefore attempting anyof the proceduresoroperationsgiven.
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PRECAUTIONS
This section providesgeneralprecautionsforusing theMotion ControlUnits(MCUnits)and related devices.
Theinformationcontainedinthis sectionisimportantforthesafeandreliableapplicationof theMotionControlUnit.
Youmustreadthis sectionand understand theinformationcontained before attemptingtosetup oroperateaMotion
ControlUnit.
1IntendedAudience xii............................................................
2GeneralPrecautionsxii...........................................................
3SafetyPrecautionsxii............................................................
4Operating EnvironmentPrecautionsxii..............................................
5Application Precautionsxiii........................................................

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1IntendedAudience
Thismanual isintended forthe following personnel,who mustalso haveknowl-
edge ofelectricalsystems(an electricalengineerorthe equivalent).
·Personnel incharge ofinstalling FAsystems.
·Personnel incharge ofdesigning FAsystems.
·Personnel incharge ofmanaging FAsystemsand facilities.
2GeneralPrecautions
The usermustoperatethe productaccording tothe performancespecifications
described inthe operation manuals.
Before using the productunderconditionswhich are notdescribed inthe manual
orapplying the product to nuclearcontrolsystems,railroad systems,aviation
systems,vehicles,combustion systems,medicalequipment, amusement
machines,safetyequipment, and othersystems,machines,and equipment that
mayhaveaseriousinfluence on livesand propertyifused improperly,consult
yourOMRONrepresentative.
Makesurethat the ratingsand performancecharacteristics of the productare
sufficient forthe systems,machines,and equipment, and be sureto provide the
systems,machines,and equipmentwith doublesafetymechanisms.
Thismanualprovidesinformation forusing the MC Unit. Besuretoread this
manualbefore attempting to usethe Unitand keep thismanualclose athand for
reference during operation.
WARNINGIt isextremeimportant thatMotion ControlUnitsand related devicesbe used for
the specified purpose and underthe specified conditions,especiallyin
applicationsthatcan directlyorindirectlyaffecthuman life.You mustconsult
withyourOMRONrepresentative before applying Motion ControlUnitsand
related devicestothe abovementioned applications.
3SafetyPrecautions
WARNINGNeverattempt to disassemble anyUnitswhile powerisbeing supplied.Doing so
mayresultinseriouselectricalshock orelectrocution.
WARNINGNevertouch anyof the terminalswhile powerisbeing supplied.Doing somay
resultinseriouselectricalshock orelectrocution.
4Operating EnvironmentPrecautions
Do notoperatethe controlsysteminthe following places.
·Wherethe PCisexposed to directsunlight.
·Wherethe ambient temperatureisbelow0°Corover55°C.
·Wherethe PCmaybe affected by condensation due toradicaltemperature
changes.
·Wherethe ambienthumidityisbelow10%orover90%.
·Wherethereisany corrosive orinflammable gas.
·Wherethereisexcessive dust, saline air,ormetalpowder.
·Wherethe PCisaffected by vibration orshock.
·Where anywater,oil,orchemicalmay splash on the PC.
OperatingEnvironmentPrecautions4

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Caution The operating environmentof the MC Unitcan have a large effecton the longev-
ityand reliabilityof the system. Improperoperating environments can lead to
malfunction, failure,and otherunforeseeable problemswiththe MC Unit. Be
surethat the operating environmentiswithinthe specified conditionsatinstalla-
tion and remainswithinthe specified conditionsduring the life of the system.
5Application Precautions
Observethe following precautionswhen using the MC Unitorthe PC.
WARNINGFailureto abide bythe following precautions couldlead toseriousorpossibly
fatal injury.Always heed these precautions.
·Always ground the systemto 100 Worless when installing the systemto pro-
tectagainstelectricalshock.
·Always turn off the powersupplytothe PCbefore attempting anyof the follow-
ing.Performing anyof the following withthe powersupplyturned on maylead
to electricalshock:
·Mounting or removing anyUnits(e.g., I/OUnits,CPU Unit, etc.)ormemory
cassettes.
·Assembling anydevicesor racks.
·Connecting ordisconnecting any cablesorwiring.
Caution Failureto abide bythe following precautions couldlead tofaultyoperation orthe
PCorthe systemorcould damage the PCorPC Units.Always heed these pre-
cautions.
·Usethe Unitsonlywiththe powersuppliesand voltages specified inthe opera-
tion manuals.Otherpowersuppliesand voltagesmaydamage the Units.
·Takemeasurestostabilizethe powersupplytoconformtothe rated supplyifit
isnotstable.
·Provide circuitbreakersand othersafetymeasuresto provide protection
againstshortsin externalwiring.
·Do notapply voltagesexceeding the rated inputvoltage toInputUnits.The
InputUnitsmaybe destroyed.
·Do notapply voltagesexceeding the maximumswitching capacitytoOutput
Units.The OutputUnitsmaybe destroyed.
·Always disconnect the LGterminalwhen performing withstand voltage tests.
·Install all Unitsaccording toinstructionsinthe operation manuals. Improper
installation may causefaultyoperation.
·Provide propershielding when installing inthe following locations:
·Locations subject tostaticelectricityorothersourcesofnoise.
·Locations subject tostrong electromagneticfields.
·Locations subject to possible exposuretoradiation.
·Locationsnearto powersupplylines.
·Besuretotighten Backplane screws, terminalscrews,and cableconnector
screws securely.
·Do notattempt totake anyUnitsapart, torepairanyUnits,ortomodifyany
Unitsin anyway.
Caution The following precautionsare necessaryto ensurethe generalsafetyof the sys-
tem.Always heed these precautions.
·Provide doublesafetymechanismsto handleincorrectsignalsthatcan be
generated bybroken signal linesormomentarypowerinterruptions.
·Provide external interlock circuits,limitcircuits,and othersafety circuitsin
addition to anyprovided withinthe PCto ensuresafety.
ApplicationPrecautions5

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SECTION1
Introduction
This section describesfundamentalsnecessaryforunderstanding thismanualand forthesuccessfuloperation ofanMCUnit.
1-1CWand CCW2............................................................
1-2FeedbackPulse2...........................................................
1-3CoordinateSystems3.......................................................
1-4ApplicableMachines3......................................................
1-5Wiring Precautions4........................................................
1-6SystemConfiguration 6......................................................
1-7OutlineoftheInterface Area 7................................................
1-8DataConfiguration 7........................................................
1-9Programsand Tasks8.......................................................
1-10 Manualand AutomaticOperation 9............................................

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1-1CWand CCW
The abbreviations“CW”and “CCW”used inthismanualto describe the opera-
tion of the MC Unitare defined asfollows:
CW(Clockwise)Clockwiseisthe direction inwhichthe presentposition increases.
Negativelimit
CW
Positivelimit
CCW(Counterclockwise)Counterclockwiseisthe direction inwhichthe presentposition decreases.
Negativelimit
CCW
Positivelimit
1-2Feedback Pulse
StandardOMRONservomotorsare designed foran advanced A-phaseforfor-
wardrotation and an advanced B-phasefor reverserotation.The MC Unitisde-
signed tocomplywiththisphase advancement, allowing OMRON DriverCon-
necting Cablestobeconnected withoutmodification.
ForwardRotation (Positive SpeedCommand)
A-phase
B-phase
Reverse Rotation (Negative SpeedCommand)
A-phase
B-phase
When using servomotorsbyothermakers,check carefullythe encoderspecifi-
cations. If the definition differsfromthe onesgiven above, take one of the follow-
ing actions:
·Reversethe B-phasewiring between the MC Unitand the servodriver.(Re-
versethe +Bterminaland the --Bterminal.)
·Set the machine parameter “encoderpolarity”inthe systemparametersto“re-
verserotation forencoderincrease.”It isinitially set tothe “forwardrotation at
the encoderincrease.”
NoteFormoreinformation on the machine parameter “encoderpolarity,” refertoMC
SupportSoftwareOperation Manual.
FeedbackPulseSection 1-2

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1-3CoordinateSystems
Positioning operationsusing the MC Unitare performed based on twocoordi-
natesystems:areferencecoordinatesystemand a workpiececoordinatesys-
tem.
The referencecoordinatesystemisthe most fundamentalone forpositioning
operations.The workpiececoordinatesystemisoffset fromthe referencecoor-
dinatesystembyaspecified amount, allowing the usertofreely setacoordinate
system.
Referencecoordinatesystem
Workpiececoordinate
system
Offsetof the workpiececoordinate
system
1-4ApplicableMachines
The MC Unithasbeen developed foruseinsimple positioning applicationsus-
ing servomotors.Depending on the machine being controlled, the accuracy of
the MC Unitshould be about fivetotenstimeshigherthat the machine being
controlled.Applicablemachinesare asfollows:
1,2,3... 1.Conveyormachinery:X/Ytables,palletizers/depalletizers,loaders/unload-
ers,etc.
2.Assembling machinery:Simplerobots(including orthogonalrobots),simple
automated assembling machines,etc.
TerminologyPalletizers/depalletizers:Devicesused forloading goodsonto palletsorforun-
loading themfrompallets.
Loaders/unloaders:Devicesthathaveshelves correspondingwiththe stepsofa
multistep press and used forinserting or removing all the materialsatone time.
ApplicableMachinesSection 1-4

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OrthogonalRobots
One-axisrobotTwo-axisrobot
The MC Unitisnotdesigned to performlinearinterpolation orcirculararcinter-
polation with horizontalarticulated robotsorcylindricalrobots.The MC Unitcan,
however,performPTPcontrolwiththeserobots.
Two-axistype
HorizontalArticulatedRobotsCylindricalRobots
Two-axistype
1-5Wiring Precautions
Heed the following precautionswhen wiring the MC Unit tothe servodriversand
motors.
Electronically controlled equipmentmaymalfunction because ofnoise gener-
ated bypowersupplylinesorexternal loads.Suchmalfunctionsare difficult to
reproduce;hence,determining the cause often requiresa greatdealof time.
The following tips should aidin avoiding noisemalfunction and improving sys-
temreliability.
Use electricalwiresorcablesofdesignated sizesas specified inthe instruction
manualforthe servodriver.Uselargersizecablesforthe FGlinesof the PCor
the driverand ground themoverthe shortestpossible distance.
Separate powercables(ACpowersupplylinesand motorpowersupplylines)
fromcontrolcables(pulse outputlinesand external inputsignal lines).Do not
group the twotypesofcabletogetherorplacetheminthe sameconduit. Use
shielded cablesforcontrol lines.
Forinductiveloads such asrelays orsolenoidvalves,connectsurge absorbers.
NoteConnectasurge-absorbing diode orsurge absorberclosetothe relay.Use a
surge-absorbing diode withavoltage tolerance atleast fivetimesgreaterthan
the circuitvoltage.
Surge-absorbing
diode Surge absorber
DC Relay AC Relay
HorizontalArticulated
Robots and Cylindrical
Robots
WiringPrecautionsSection 1-5

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Solenoid
Surge absorber
Noisemaybe generated on the powersupplyline if the same powersupplyline
isused foran electricwelderorelectricaldischarge unit. Provide an insulating
transformerand a line filterinthe powersupply section toremovesuch noise.
It isrecommended that twisted-paircablesbe used forpowersupplylines.Use
adequate grounds(i.e., to 100 Worless)with a wirecross section of1.25 mm2or
greater.
Usetwisted-pairshielded cablesforthe controlvoltage outputsignalsand the
feedback inputsignals.
Forthe controlvoltage outputsignals,wireamaximumof twometersbetween
the MC Unitand the servodriver.
MC Unit
Voltage output
2m max.
Servodriver
Wirethe distance between the MC Unitand the feedback pulse generator (i.e.,
encoderorthe servodriver) asfollows:
·When the feedback pulseisoutput fromaline driver,wireamaximumlength of
20 meters.
MC Unit
20 m max.
Feedback input
Servodriveror
encoder
LineDriverOutput
NoteThe input terminalsthatoperatethe 24-Vsystemareisolated with photocoup-
lerstoreduce externalnoise effectson the controlsystem.Avoidconnections
between the analog controlvoltage ground (AG)and the 24-Vsystemground
(DC GND).
WiringPrecautionsSection 1-5

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1-6SystemConfiguration
The following diagrams showsan overviewof the systemconfiguration of the
MC Unitand related devices.
MC Unit
MC
Support
Software
Data
PC
XaxisYaxis
MCprogram
(Glanguage)
System
parameters
Position data
Registers
Interface area
Teaching
Box
or
M M
The MC Unitreceives commandsfromthe PCthrough the interface area and
executesthe MCprogramtocontrolthe servomotors completelyindependent
fromthe ladder-diagramprogramof the PC.
The MCprograms,systemparameters,and position datathatarerequired for
operating the MC Unitaresetusing the MCSupportSoftware.
NoteForfurtherinformation on the MCprogram(Glanguage),refertoSection 6 G
Language.
Forfurtherinformation on the MCSupportSoftware and the Teaching Box,refer
toSection4SystemConfiguration.
Forfurtherinformation on the interface area,referto1-7Outline of the Interface
Area and 7-5InterfaceArea.
Forfurtherinformation on data,referto1-8DataConfiguration.
SystemConfigurationSection 1-6