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Faulhaber MC 5010 Technical Manual

Motion controllers
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MC 5010
MC 5005
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WE CREATE MOTION

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Summary of Contents for Faulhaber MC 5010

  • Page 1 Technical Manual MC 5010 MC 5005 WE CREATE MOTION...
  • Page 2 Dr. Fritz Faulhaber GmbH & Co. KG. This document has been prepared with care. Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any liability for any errors in this document or for the consequences of such errors. Equally, no liability can be accepted for direct or consequential damages resulting from improper use of the equipment.

  • Page 3: Table Of Contents

    Content About this document ....................... 5 Validity of this document ..................5 Associated documents .................... 5 Using this document ....................5 List of abbreviations ....................6 Symbols and markers ..................... 7 Safety ..........................8 Use for the intended purpose ................8 Safety instructions ....................
  • Page 4 Content Warranty ......................... 44 3rd edition, 6-11-2017 7000.05057, 3rd edition, 6-11-20177000.05057...

  • Page 5: About This Document

    Description Motion Manager 6 Operating instructions for FAULHABER Motion Manager PC software Quick start guide Description of the first steps for commissioning and operation of FAULHABER Motion Controllers Drive functions Description of the operating modes and functions of the drive...

  • Page 6: List Of Abbreviations

    About this document List of abbreviations Abbreviation Meaning Alternating Current AnIn Analogue Input AnOut Analogue output AGND Analogue Ground CAN_L CAN-Low CAN_H CAN-High Clock Command Specifier Direct Current DigIn Digital input DigOut Digital output Electromagnetic compatibility Electrostatic discharge EtherCAT (Ethernet for Control Automation Technology) Ground Programmable Logic Controller Pulse Width Modulation...

  • Page 7: Symbols And Markers

    About this document Symbols and markers CAUTION! Hazards due to hot surfaces. Disregard may lead to burns.  Measures for avoidance NOTICE! Risk of damage.  Measures for avoidance Instructions for understanding or optimising the operational procedures  Pre-requirement for a requested action 1.

  • Page 8: Safety

    Safety Safety Use for the intended purpose The Motion Controllers described here are designed for use as slaves for control and posi- tioning tasks for the following motors: DC motors  Linear DC-Servomotors   Brushless DC motors The Motion Controller is suitable in particular for tasks in the following fields of applica- tion: ...

  • Page 9: Safety Instructions

    Safety Safety instructions NOTICE! Electrostatic discharges can damage the electronics.  Wear conductive work clothes. Wear an earthed wristband.  NOTICE! Penetration of foreign objects can damage the electronics.  Do not open the housing. NOTICE! Inserting and withdrawing connectors whilst supply voltage is applied at the device can damage the electronics.

  • Page 10: Ec Directives On Product Safety

    Therefore the Machinery Directive does not apply to our products. The products described here are not "incomplete machines". Therefore installation instructions are not normally issued by FAULHABER. Low Voltage Directive (2014/35/EU) The Low Voltage Directive applies for all electrical equipment with a nominal voltage of 75 to 1500 V DC and 50 to 1000 V AC.

  • Page 11: Product Description

    The output stages are exchangeable and are matched to the various sizes and types of motors, i.e. DC, BL and LM motors from 12 – 44 mm, as listed in the FAULHABER product portfolio.

  • Page 12: Product Information

    Product description Product information … … RS: Serial Interface RS 232 CO: Interface CANopen ET: Interface EtherCAT S: Housing with Connectors/Terminals 05: Continuous Output Current 5 A 10: Continuous Output Current 10 A 50: Max. Supply Voltage 50 V MC: Motion Controller Fig.

  • Page 13: Product Variants

    Product description Product variants The housed variant of the Motion Controller is available in 2 formats. 3.3.1 Standard format The standard format of the housed Motion Controller has a CANopen or RS232 interface. The USB interface is available in all devices. 3.3.1.1 Motor side of the standard format Motor •...

  • Page 14: Extended Format

    Red (continuously flashing): The drive has switched to a fault state. The output stage will be  switched off or has already been switched off.  Red (Error code): Boot procedure failed. Please contact FAULHABER Support. Green: Power supply within the permissible range.  Power LED Off: Power supply not within the permissible range.

  • Page 15: Supply Side Of The Extended Format

     Red (continuously flashing): The drive has switched to a fault state. The output stage will be switched off or has already been switched off. Red (Error code): Boot procedure failed. Please contact FAULHABER Support.   Green: Power supply within the permissible range.

  • Page 16: Installation

    Installation Installation Mounting Only trained experts and instructed persons with knowledge of the following fields may install and commission the Motion Controller: Automation technology  Standards and regulations (such as the EMC Directive)   Low Voltage Directive Machinery Directive ...

  • Page 17: Attachment Via The Side Plates

    Installation NOTICE! Installation and connection of the Speed Controller when the power supply is applied can damage the device.  Prior to all aspects of installation and connection work on the Speed Controller, switch off the power supply. 4.1.2 Attachment via the side plates NOTICE! Installation of the Motion Controller on a surface that is not flat can lead to the Motion Controller becoming damaged.

  • Page 18: Installation On A Top-Hat Rail

    Installation 4.1.3 Installation on a top-hat rail The top-hat rail adapter is available as an accessory, see the Accessories Manual. Fig. 7: Installation on a top-hat rail Motion Controller Countersunk screw Top-hat rail adapter 1. Using countersunk screws (3), screw the top-hat rail adapter (2) onto the Motion Con- troller (1).

  • Page 19: Installation With Top-Hat Rail Clips

    Installation 4.1.4 Installation with top-hat rail clips Top-hat rail clips are not part of the FAULHABER product portfolio, they must be pro- vided by the user (recommendation: Mounting foot, WAGO item number 209-188). Fig. 8: Installation with top-hat rail clips...

  • Page 20: Electrical Connection

     For applications with high load inertia, the FAULHABER Braking Chopper of the BC 5004 series can be used to limit overvoltages and thereby protect the power supply. For more detailed information see the data sheet for the Braking Chopper.

  • Page 21: Connections At The Motor Side

    Installation Motion Drive Controller Neutral point Fig. 9: Potential equalisation between electrically connected parts of the system 4.2.2 Connections at the motor side The maximum length of the cable between the Motion Controller and motor depends on the sensor system used and the electrical and magnetic fields in the environment. Tab.

  • Page 22: Screening

    Installation 4.2.3 Screening Motor C Phase C Motor B Phase B Motor A Phase A Cable Shield Brushless SGND DC-Servomotor Sensor C Hall Sensor C Sensor B Hall Sensor B Sensor A Hall Sensor A Cable Shield Fig. 10: MC 50xx connection of a BL servomotor Mot –...

  • Page 23: Connection At The Supply Side

    Installation 4.2.4 Connection at the supply side Connections at the supply side: Discrete inputs and outputs (for instance for discrete target values preselection or for  connection of limit switches / reference switches) Communication connections   Make sure that the connection cables to the connection side are not longer than 3 m. ...

  • Page 24: Connector Pin Assignment

    Connection to motor phase C Tab. 9: Electrical data for the motor connection (M1) Designation Value Power supply for motor 0...U max. 5/15 A (type MC 5005) or 10/30 A (type MC 5010) 100 kHz 3rd edition, 6-11-2017 7000.05057, 3rd edition, 6-11-20177000.05057...
  • Page 25 Tab. 11: Electrical data for the DC motor connection (M1) Designation Value Power supply for motor 0...U max. 5/15 A (type MC 5005) or 10/30 A (type MC 5010) 100 kHz Sensor connection (M2) Tab. 12: Pin assignment at the sensor connection (M2) Designation Meaning...
  • Page 26 Installation Encoder connection (M3) The pin assignment of the encoder connector varies depending on the encoder type. Incremental encoder with or without line driver  Absolute encoder with or without line driver.  Tab. 14: Pin assignment for incremental encoder with line driver (M3) Designation Meaning Power supply for the incremental encoder...
  • Page 27 Installation Tab. 17: Electrical data for incremental encoders without line driver (M3) Designation Value Power supply for incremental encoder <100 mA Connection port for incremental <5 V encoder <2 MHz 5 kΩ Tab. 18: Pin assignment for absolute encoders with line driver (M3) Designation Meaning Power supply for absolute encoder...

  • Page 28: Pin Assignment At The Supply Side

    Installation Tab. 21: Electrical data for absolute encoders without line driver (M3) Designation Value Absolute encoder power supply <100 mA Command Specifier connection port 5 V Connection port for data <5 V 5 kΩ Connection port for clock 1 MHz 4.2.5.2 Pin assignment at the supply side Status...
  • Page 29 Installation COM port (X2) The pin assignment at the COM port differs according to the type of communication. The distinction is made between the following types of communication: RS232  CANopen  Tab. 23: Pin assignment at the COM port (X2) for RS232 Designation Meaning RS232 interface transmit direction...
  • Page 30 Installation Tab. 26: Electrical data for the I/O port (X3) Designation Value Power supply for external consumer load <100 mA DigOut low = GND high = high resistance 47 kΩ max. 0.7 A TTL level: low < 0.5 V, high > 3.5 V PLC level: low <...
  • Page 31 Installation Power supply of the motor (X5) Tab. 29: Pin assignment for the power supply of the motor (X5) Designation Meaning Ground Supply voltage of the motor Tab. 30: Electrical data for the power supply (X5) Designation Value ≤50 V Power supply for motor EtherCAT port (IN/OUT) Tab.

  • Page 32: Connection At The Motor Side

    Installation 4.2.6 Connection at the motor side Motor A Motor Phase A BL-Motor Motor Phase B Motor B Motor C Motor Phase C +5 V Power Supply Sens A Hall Sensor A Sens B Hall Sensor B Sens C Hall Sensor C Fig.
  • Page 33 Installation Motor A Motor Phase A Motor B Motor Phase B BL-Motor Motor C Motor Phase C +5 V Power Supply 1 3 5 7 Data Data 2 4 6 8 Data Data Fig. 17: BL motor with absolute encoder 3rd edition, 6-11-2017 7000.05057, 3rd edition, 6-11-20177000.05057...
  • Page 34 Installation Motor A Motor Phase A BL-Motor Motor B Motor Phase B Motor C Motor Phase C +5 V Power Supply Sens A Hall Sensor A Sens B Hall Sensor B Sens C Hall Sensor C +5 V Encoder Supply 1 3 5 7 Channel A Encoder Channel A...
  • Page 35 Installation Motor A Motor Phase A Motor B Motor Phase B BL-Motor Motor Phase C Motor C +5 V Power Supply Sens A Hall Sensor A Sens B Hall Sensor B Sens C Hall Sensor C +5 V Power Supply 1 3 5 7 Data Data...

  • Page 36: I/O Circuit Diagrams

    Installation 4.2.7 I/O circuit diagrams AGND – AnIn Fig. 20: Analogue input circuit diagram (internal) So that the voltage drop on the supply side does not affect the speed specification value, connect the analogue input ground (AGND) to the power supply ground (GND). The analogue inputs are executed as differential inputs.

  • Page 37: External Circuit Diagrams

    Installation DigOut DigOut Fig. 22: Digital output circuit diagram (internal) The digital output has the following properties:  Open collector switch to ground  Monitored output current (switch opens in the event of an error) A digital output can be assigned to an error output. It can be programmed freely. 4.2.8 External circuit diagrams Bipolar analogue set value specification via potentiometer...
  • Page 38 Installation Analogue set value specification via potentiometer with internally set offset and scaling Motion Controller AnIn AGND – Interface Fig. 24: Analogue set value specification via potentiometer with internally set offset and scaling Connection of reference and limit switches Motion Controller DigIn X DigIn Y Limit Switch...
  • Page 39 Installation Connection of an external incremental encoder 2,7k DigIn1 DigIn2 Quadrature Encoder Counter DigIn3 Index Index Interface Fig. 26: Connection of an external incremental encoder Depending on the type of encoder it may be necessary to use additional pull-up resis- tors.
  • Page 40 Installation Wiring with several Motion Control Systems in RS232 network operation PC or Node 1 Node n High Level Control 4,7k Fig. 28: Wiring with several Motion Control Systems in RS232 network operation Depending on the number of networked controllers a smaller value may be necessary for the pull-down resistor.

  • Page 41: Maintenance And Diagnostics

    Red (continuously flashing): The drive has switched to a fault state. The output stage will be  switched off or has already been switched off. Red (Error code): Boot procedure failed. Please contact FAULHABER Support.  Green: Power supply within the permissible range.

  • Page 42: Troubleshooting

    Red (continuously flashing): The drive has switched to a fault state. The output  stage will be switched off or has already been switched off.  Red (Error code): Boot procedure failed. Please contact FAULHABER Support. Green: Power supply within the permissible range.  Power LED Off: Power supply not within the permissible range.

  • Page 43: Accessories

    Accessories Accessories Details of the following accessory parts can be found in the Accessories Manual: Connection cables  Connectors   Connector sets  Installation materials Additional equipment  3rd edition, 6-11-2017 7000.05057, 3rd edition, 6-11-20177000.05057...
  • Page 44 Warranty Warranty Products of the company Dr. Fritz Faulhaber GmbH & Co. KG are produced using the most modern production methods and are subject to strict quality inspections. All sales and deliv- eries are performed exclusively on the basis of our General Conditions of Sale and Delivery which can be viewed on the FAULHABER home page www.faulhaber.com/gtc and down-...
  • Page 45 DR. FRITZ FAULHABER GMBH & CO. KG Antriebssysteme Daimlerstraße 23 / 25 71101 Schönaich • Germany Tel. +49(0)7031/638-0 Fax +49(0)7031/638-100 info@faulhaber.de www.faulhaber.com 7000.05057, 3rd edition, 6-11-2017 © Dr. Fritz Faulhaber GmbH & Co. KG...

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Mc 5005

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