Omron C500-TU001 3G2A5-TU001 PLC Teaching Box

The Omron C500-TU001, also designated as model 3G2A5-TU001, is a position control teaching device designed specifically for the SYSMAC C500 series programmable logic controllers. This specialized unit enables operators to program single-axis positioning sequences through a manual teaching process, storing position coordinates for later playback during automated machine operation. The teaching box serves as an interface between operators and the motion control system, simplifying the process of defining positions, speeds, and sequences for axes controlled by the C500 PLC.

Position Control Architecture

The C500-TU001 implements incremental position control methodology, where position commands are expressed as relative movements from the current location rather than absolute coordinates referenced to a fixed origin. This approach is well suited to applications involving repetitive point to point movements where relative distances between positions remain consistent while the absolute reference may vary. The teaching box supports single-axis control, providing complete concentration of motion programming resources on one axis for straightforward positioning tasks including pick and place operations, transfer equipment positioning, indexing table rotation, and conveyor stop positioning.

Manual Teaching Operation

The teaching box accepts manual teaching inputs where the operator manually moves the axis to desired positions, recording the coordinates into the units memory for later playback. This teaching method is intuitive for operators familiar with the physical machine operation, allowing positions to be defined by direct manipulation rather than numerical coordinate entry. The teaching process typically involves jogging the axis to the first desired position, pressing a record button to store the coordinates, moving to the next position, and repeating until all required positions are programmed. The stored position data can be reviewed and edited as needed, with individual positions modifiable without re-teaching the entire sequence.

Feedback and Positioning Accuracy

Position accuracy is maintained through closed-loop feedback from an encoder or similar position-sensing device, which reports actual axis location back to the control system for comparison against commanded position. The encoder provides continuous monitoring of axis movement, enabling the controller to detect and correct deviations from the intended path. This feedback mechanism compensates for mechanical variations including belt stretch, gear backlash, thermal expansion, and other factors that could otherwise degrade positioning precision. The control system calculates position error as the difference between target and actual locations, applying corrective signals to the drive amplifier to minimize this error and achieve the desired final position within the system accuracy specification.

Operating Modes

The C500-TU001 provides two primary operating modes that serve different phases of machine use. TEACHING mode is active during system setup and programming, allowing operators to manually position the axis and record coordinates into memory. PLAYBACK mode is used during normal production operation, causing the system to execute the programmed positioning sequence automatically, moving the axis through the recorded positions in sequence. Some systems incorporate additional operational options including single step execution for verification of programmed positions, continuous cycling for production runs, and position verification for quality checking. The teaching box includes status indicators that communicate current mode, axis position, error conditions, and other operational information to the operator.

System Integration and Memory

The C500-TU001 mounts into a designated slot in the SYSMAC C500 rack, connecting to the backplane for power and communication with the PLC CPU. The teaching box is compatible with C500 power input voltage ranges, integrating with the existing system power supply without requiring separate power connections. Battery-backed memory ensures programmed position data remains intact during power interruptions, with a backup battery maintaining memory contents when main power is removed. This non-volatile storage eliminates the need to re-teach positions after maintenance or facility power outages, preserving previously configured motion sequences for immediate operation upon power restoration.